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GS-1930

1. I LI I P1 NC 51F C 7 D nm 76F 50F 49F 5 muU Ground Controls NO NO before serial number 21065 and from serial number 40926 to 52966 A11 A11 KEY SWITCH G6 KSI r 48F TS66 1 GROUND O mO UP a 202 1 N O N O HO FT 29F H O wor DOWN 53F NC 51F C 41F nu 45 B12 12 24F B 76F WW mu 54 49F gt KSI T PLATFORM NO NO O10 Ground Controls from serial number 21065 to 40925 Hi E E A11 A11 KEY SWITCH 2 i EB r 48F TS66 P1 o UP CB2 NO NO CI II DOWN 5 NC O 518 Ir 45F Bi2 12 s m E v PEN ABBREVIATION LEGEND Item Description CB2 Circuit breaker 7A G6 Hour meter KS1 Key switch P1 Emergency Sto TS66 Platform up down toggle switch Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics EES E Level Sensor Box Wiring Diagram
2. Da 7 1 TE WH RD WH A A M KS1 gt KCN AN BL B B KEY SWITCH POWER 4 BK D DH d RELAY 5 s TOUS oR E E CB2 P1 a LLL e 7A EMERGENCY A e CIRCUIT STOP An 2 BREAKER 39C N C NO 1 N CHO 4 i LS6 H5 PS2 LS7 DOWN ALARM PLATFORM POTHOLE LIMIT OVERLOAD GUARD zig SWITCH PRESSURE SWITCH 3 TS66 SWITCH PLATFORM OPTION N C HO 4 UP DOWN SWITCH O 8 S LS8 3 POTHOLE GUARD SWITCH 30 86 CR5 i N O i 0 U27 ia w gt gt gt gt o m o moog gt A ONER B E E 3 9 2 5 5 FEN i 4 47 mH INDUCTOR t hs H2 OPTION lr amp Po ER z m S lt so 33 E t NOISE SUPPRESSION 918 9 5 3 4 5 amp 255 LE LEVEL 2 g 9 2 o 2 2 i X gt o 2 SENSOR MODELS ONLY 9 o E 3 z E c o Q 2 5 5 9 CIRCUIT AFTER SERIAL NUMBER 50511 R21 ag 8 o oda E 9 m R 9 B 9 2 5 BOARD 75 OHM 21254 4 3I 2 2 2 5 2 g Z S E z i 8 amp S7 8 3 4 Eve QD1 m 9 MENS Si 5 1 a
3. 1 76F 78F WH ra RD 4 TF f WH WH 3 dun 30 86 MW N FON KS1 CR48 WH BL 1 1 0 lan KEY SWITCH POWER Wa ee p RELAY 87 85 9s TO US WH OR 5 CB2 P1 535 7A EMERGENCY CIRCUIT STOP BREAKER 2 39C N C 4 NO 4 N C H O 4 C F LS6 H5 PS2 LS7 DOWN ALARM PLATFORM POTHOLE LIMIT OVERLOAD GUARD 21 SWITCH PRESSURE SWITCH TS66 SWITCH PLATFORM OPTION N C H O 3 UP DOWN SWITCH 8 S LS8 3 POTHOLE GUARD SWITCH 2 30 86 i U27 CR5 ol gt gt gt m0 o w w g mo gog gt ae gt HORN RELAY gt MS lt 2 5 a m i 47 mH INDUCTOR uw 95 H2 OPTION Els amp p a 6 3 3 i ok 4 NOISE SUPPRESSION 18 S I I E 5 555 Fi LEVEL 2 g g 3 z a 2 d Q T 4 2 SENSOR CE MODELS ONLY 9 2 32 5 5 gt E o g ms 9 CIRCUIT AFTER SERIAL NUMBER 50511 R21 2 9 8 2 E a 952 3 ri BOARD g F4 7 2 tz m 2 3 3 ag oi a lig 2 o A 57 E n 3 LEVEL QD1 m g tL Pee v ZEE BN 5 F6 _ e 275A FUSE D1 Le p m c B8 A
4. TOF gE WH RD Sate des up Ui ee dco E eto ACERO 7 WH A A RN KS1 i CR48 0 86 M KEY SWITCH chi BL B B i BK D D FON T RELAY 87 85 me ee TO US OR E E We a E UE oo S I1 s sm yo i memet CB2 P1 B 280 EMERGENCY T r t 2 CIRCUIT STOP BREAKER i PLATFORM aud 1 39C i 1 T al NC 4 NO N C H O 4 5 O 2 LS6 H5 PS2 LS7 GROUND i DOWN ALARM PLATFORM POTHOLE CONTROL LIMIT OVERLOAD GUARD SWITCH PRESSURE SWITCH 3 TS66 SWITCH PLATFORM OPTION N CHO 4 UP DOWN SWITCH 8 S LS8 3 POTHOLE GUARD SWITCH 1 30 86 U27 CR5 2l gt gt m0 o w w g m o gg cd ANO 4 OE HORN RELAY o 2 n o 9 D Oz 5 a 47 mH INDUCTOR i SE vor Y O Hd I 6 NOISE SUPPRESSION pre IB ee OPTION 915 6 S S68 g Bg 3 m E RI S 9 9g 5 3 m gt E 5 Q 2 QI 5 5 g LEVEL 3 3 2 E gt 3 g RR 9 21 SENSOR i CE MODELS ONLY ES o o 5 5 s E Q mice 5 9 CIRCUIT 1 AFTER SERIAL NUMBER 50511 R21 89 2 g a E 952 2 21 BOARD e 2 xo 1 75
5. REV A 56 Level Sensor after serial number 21064 S7 B9 44D H5 gt B11 39C 4 N RD BK WH A5 C11 70D p 0 29F 27D 44D A 75D 23D C12 7 L LS6 Level Sensor before serial number 21065 57 B9 5 N N C B11 e _l_e 39C HD O A5 70D C11 75D 29F 27D X L aap 7 wal 7 23F C12 WIRE COLOR LEGEND ABBREVIATION LEGEND Color Description Item Description BK Black H5 Multi function alarm RD Red LS6 Down limit switch WH White S7 Level sensor Part No 72876 Genie GS 1530 and GS 1930 6 11 Section 6 Schematics April 2003 Electrical Symbols Legend J18VN3 HLNOO HOLOW 8V Wire with description Circuits crossing no connection Diode Connection no terminal l Y Connector Flashing beacons FB1 PS2 2 Pressure switch normally closed om B T f Limit switch Toggle switch CN 1 _ Emergency Stop button Normally closed KON CB2 Circuit breaker Horn or alarm amp LED Q M BO OT BO A2 30 30 B 10 Motor controller
6. Electrical Schematic PEVE from serial number 49805 to 51014 QD4 gera E WH RD WH A C A AN N KS1 48 30 86 MY KCN KEY SWITCH M cni BL B B 7 RELAY s Tes BK D ay r e e e o oe TOUS OR E E CB2 P1 p Lh W Wot wm 7A EMERGENCY i t t OT CIRCUIT STOP BREAKER i PLATFORM T I CONTROL 1 T NO N C H O 4 OF D LS6 H5 52 157 GEOUND DOWN ALARM PLATFORM POTHOLE me SWITCH PRESSURE SWircH TS66 SWITCH PLATFORM OPTION N CHO 4 UP DOWN SWITCH 8 S LS8 3 POTHOLE GUARD SWITCH p S P4 1 30 86 7 085 47 mcd Jo HORN RELAY i E 2 2 9 E 2 g 8 2 g S 9 amp mi Eo d lt gt gt NOISE SUPPRESSION 18 8 5 3 5 9 5 235E 5 2 9 O9 3 2 MODELS ONLY D d 5 ae RR 2 6 5 2 2 Dc Gee o 2 AFTER SERIAL NUMBER 50511 R21 2 9 8 o od 5 m m m Speg 2h 75 OHM 213 amp md 2 F 2 5 S o 7v E 5 1 to i amp E 2 57 5 3 LEVEL m g SENSOR ON Los r BN F6 e 275A FUSE Lo LL B8 A9 A12 B12
7. REV M L K ABBREVIATION LEGEND Item Description 5 Battery BN Button BN5 Horn Lift enable CB2 Circuit breaker 7A CR5 Horn relay with H2 option D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform R Resistor R15 5000 ohm potentiometer R21 75 ohm resistor 57 Tilt level sensor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switch TS66 Platform up down toggle switch U Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Y Valve coil Y2 B
8. REV Hydraulic Schematic from serial number 17408 to 35799 M L K J H G F E D B A LEFT RIGHT LEFT RIGHT CYLINDER BRAKE ri BRAKE DRIVE MOTOR DRIVE MOTOR 1 STEER STEER MM C M LEFT RIGHT N HAND 1 4 PUMP d eee Ds9 L 1 oll Bro 9 i D 9 2 mmm X 4 US IL MANUAL E 85 1880 0 046 1 17 mm RELEASE 65 1930 0 037 0 94 C o f tse _ e e e u 0 The lift cylinder orifice is located S1 52 LIFT underneath the fitting on the lift cylinder BRAKE HP M1 M3 M2 M4 3 NL C AORE Y4 Wi MA si AEN AK E Leti 4 LY O H Ne EM TP LN 2 7 f ap 1500 psi AD ve i v vs l AB A 103 4 bar 0 040 E 7 5 0 75 gpm J SEE id S Al 2 8 L min 5 psi AJ 0 35 bar lt AG D _ t L FUNCTION MANIFOLD PRESSURE TANK 7 ABBREVIATION LEGEND k Description POWER AA Test port x 4 o Flow regulator steer circuit E x ee BYPASS Relief valve system ABBREVIATION LEGEND AD Orifice washer steer circuit joo MESH e L Ll 22 Item Description AE Relief valve steer A Check valve manual brake relea
9. 02 100001000 03 joooto00 e 04 90100000 3 e p 31 05 jorooo00 e I 06 fele 07 jooototo e e 08 oo1o0100 e e 09 jorooto e e 10 j0o0tit00 elele L ww Teoronioo T eg pere T 12 010011001 e fete 13 ete je i4 jorooto e e je 1 ormote Tepep p e p 16 1 Bae Co pw _18__ 01101100 efe ete s perse 20 ormeo _21__ 00011000 ele 22 00100000 23 010010001 e 1111 24 0011100011 elef 25 jorotioo e efe 1011010600 p er Jonmoo ie 28 jootto000 ele 20 010100001 1 30 efel 31 01100000 eje REV B DIP Switch Function Definitions If replacing the circuit board note the toggle positions on the DIP switches Set the DIP switches on the new circuit board to the same configuration of the old board Motion Beacon The motion beacon option flashes only when operating a function Motion Alarm The motion alarm will sound when operating any function Lift Drive Cut Out This cuts out lift and drive functions when the machine e
10. 6 23 Electrical Schematic from serial number 40926 to 49804 Rev 6 25 Part No 72876 Genie GS 1530 and GS 1930 ix April 2003 TABLE OF CONTENTS Section Six Schematics continued Electrical Schematic from serial number 49805 to 51014 Rev B 6 27 Electrical Schematic from serial number 51015 to 52966 Rev 6 29 Electrical Schematic from serial number 52967 to 53999 Rev 6 31 Electrical Schematic from serial number 54000 to 59999 Rev 6 33 Hydraulic Schematic Legend and Component Reference Rev 6 35 Hydraulic Schematic from serial number 17408 to 35799 Rev 6 36 Hydraulic Schematic from serial number 35800 to 59999 Rev 6 37 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 2 Specifications REV Machine Specifications GS 1530 Specifications Performance Specifications GS 1530 Batteries Type 6V DC Drive speed maximum Group T 105
11. 1 Number 4 pivot pin steer end 11 Number 4 pivot pin non steer end 2 Number 3 center pivot pin 12 Number 3 inner arm 3 Lift cylinder rod end pivot pin 13 Number 3 outer arm 4 Number 3 pivot pin steer end 14 Number 3 pivot pin non steer end 5 Number 2 center pivot pin 2 pins 15 Lift cylinder 6 Number 2 inner arm 16 Number 2 outer arm 7 Number 2 pivot pin steer end 17 Number 2 pivot pin non steer end 8 Number 1 center pivot pin 18 Lift cylinder barrel end pivot pin 9 Number 1 inner arm 19 Number 1 outer arm 10 Number 1 pivot pin steer end 2 pins 4 18 Genie GS 1530 and GS 1930 Part No 72876 April 2003 EEE REV A 3 1 Scissor Assembly GS 1530 How to Disassemble the Scissor Assembly GS 1530 1 AWARNING 20dily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the side of the number 3 outer arm index 13 at the ground controls side Component damage
12. T Battery charger 6V battery Resistor 75 ohm Inductor noise suppression i Lo R15 i 5000 ohm to POTENTIOMETER i SW5 0 FUNCTION N HALL lo GENERATOR ih 1 I 1 I REV GROUND CONTROL LEVEL SENSOR i LEVEL SENSOR ccur Boano Level sensor E Solenoid valve EX Solenoid valve with diode 1 JC1 JOYSTICK CONTROLLER Genie GS 1530 and GS 1930 Part No 72876 Section 6 Schematics April 2003 Electrical Schematic from serial number 17408 to 21064 A B 1 2 3 4 5 F6 275A FUSE Ne 6 U9 BATTERY CHARGER BS AC INPUT BATTERY em i T d FUSE U13 l DC AC INVERTER OPTION 8 6 13 Genie GS 1530 and GS 1930 Part No 72876
13. 1 PRU Flashing beacon 39676 ECCO Electronic Controls 6220A issu 2 GG EE Hour meter before serial number 21065 19506 ENM Corporation T40A4508 1 from serial number 21065 to 40925 56100 Curtis Instruments 17305666 1 after serial number 40925 19506 ENM Corporation T40A4508 1 H1 H5 Alarm steady tone 39540 Floyd Bell Inc UC 09628 Q 1 Alarm 24V DC 81579 Hella 95346 12 1 KS uuu Contact key switch N O before serial number 37962 45081 Telemecanique ZB2 BE101 1 from serial number 37962 to 529696 66816 Telemecanique ZBE 101 oiiire 1 after serial number 52966 96008 PODS e 88652 iiie 1 ERR Contact limit switch N C 19491 Telemecanique XESP2151 um 1 LS7 LS8 Contact limit switch N C H O 19491 Telemecanique XESP2151 2 Contact N C befor
14. 4 2 1 2 JOYSTICK COMMONS pu cre due tae 4 3 13 Controller Adjustments 4 5 1 4 Software Configuration 4 12 Platform Components RevA 2l PRVOM M 4 16 2 2 Platform Extension 4 17 vi Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section Four TABLE OF CONTENTS Repair Procedures continued Scissor Components RevA 3 1 Scissor Assembly 65 1530 eet ev E a nd 4 18 3 2 Scissor Assembly GS 1930 22 2 4 24 ccu dem 4 32 Ground Controls Rev B 4 1 Manual Platform Lowering Cable ssseeeeeeennennne 4 34 4 2 Toggle Switches sia erinridn naminiais aiani raidean aan inea iiad adia 4 36 4 3 Control Relay Snai E 4 37 4 4 Tilt Level Sensor before serial number 50444 4 38 4 5 Tilt Level Sensor after serial number 50443 4 46 Hydraulic Pump Rev B Bail x Vino PUN TEES 4 54 Function Manifold Rev B 6 1 Function Manifold Components from serial number 17408 to 35799 4 56 6 2 Function Manifold Components after serial number 35799 4 58 6 3 Valve Adjustments Function Manifold eeeeeeeee 4 60 6 4 Valve
15. 25 30 ft lbs 34 41 Nm 4 74 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in stowed position Key switch in the off position with the key removed Wheels chocked Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie GS 1530 and GS 1930 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate flow chart thoroughly Attempting shortcuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing ADANGER or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Contact with electrically charged circuits could result in
16. 1 O PIO3 VOLTAGE REGULATOR SW25 DIP SWITCHES POUT1 POUT2 POUT3 POUT4 POUTS POUT6 POUT7 POUT8 POUT9 O POUT10 U3 PLATFORM CONTROLS PLATFORM CONTROLS PRINTED CIRCUIT BOARD PIN1 PIN2 POUT11 O Section 6 Schematics from serial number 54000 to 59999 B A p P2 EMERGENCY STOP 1 JC1 JOYSTICK NS CONTROLLER X swe STEER LEFT RIGHT do qp 2 L 4 4 SW5 FUNCTION 3 POWER LED L19 FAULT LED L25 HIGH TORQUE LED L21 BATTERY LEVEL 1 BATTERY LEVEL2 4 BATTERY LEVEL3 gt 37 BATTERY LEVEL 4 BATTERY LEVEL 5 DRIVE LED L17 LIFT LED L16 MEMBRANE DECAL PANEL 5 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 6 CONTROLLER 8 Part No 72876 Genie GS 1530 and GS 1930 6 34 April 2003 Section 6 Schematics dl Electrical Schematic from serial number 54000 to 59999 Section 7 Schematics April 2003 M M i Hydraulic Schematic Legend and Component Reference Section 6 Schematics April 2003 Hydraulic Schematic Legend and Component Reference AK Function manifold components from serial number 17408 to 35799 BB BC QP Function manifold com
17. 1 76F 78F WH RD C reuse eee e eee 2E WH A A KS1 CR48 30 86 KEY SWITCH T d BL B lt B 7 POWER FON T RELAY s Tes BK D 2 pe ote TOUS OR E E CB2 P1 B 23D 7A EMERGENCY e CIRCUIT STOP 2 BREAKER PLATFORM CONTROL 39C nu 5 N C 4 NO 1 N C HO i D _ C i X Ls6 H5 PS2 LS7 GRGUND DOWN ALARM PLATFORM POTHOLE V CONTROL LIMIT OVERLOAD GUARD 21B EE Ge all SWITCH PRESSURE SWITCH 3 TS66 SWITCH PLATFORM OPTION N C HO UP DOWN SWITCH 8 S LS8 3 POTHOLE GUARD SWITCH i 30 86 CR5 4 6 S gt 8 2 2 2 225 2 UR d ip ip m o mu e5 H2 OPTION 8 amp F 5 E D x 5 i 3 E E I 3 f n 5 D T 2 55 S pi LEVEL 2 s 2 e az 2i SENSOR o 3 3 o m d d S28 Gi CIRCUIT Q Q 2 2 gt z o E z em p EE o Di R21 9 2 2 3 58 8 m m bass Q 2 gt BOARD i g f d d g g gt 2 amp 9 t i o 9 3 s U27 gt o 8 S7 47 mH D 3 LEVEL INDUCTOR 5 SENSOR m 1 QD1 NOISE 2 i 5 SUPPRESSION ete F6 275A FUSE D1 m B8 AB A9 A12 B12 A11 C12 B9 A10 B10 C2 A4 B11 A2 B1 Ci C11 A5 OUT OUT N IN IN OUT IN IN IN IN IN IN IN IN IN OUT eM Y 1 1
18. rtt Er Re C E ER 4 66 Hydraulic Tank Rev A 7 4 Hydraulic WANK een 4 68 Steer Axle Components Rev B 8 1 Yoke and Drive Motor pe SURE REC REY dienes 4 69 8 2 Steer Oylin det ioci be cete EE 4 71 8 8 nnns 4 72 Non steer Axle Components Rev 9 1 Drive Brake 4 73 Brake Release Hand Pump Components Rev 10 1 Brake Release Hand Pump 4 74 Part No 72876 Genie GS 1530 and GS 1930 vii April 2003 a TABLE OF CONTENTS Section Five Troubleshooting Flow Charts and Fault Codes ee E E E 5 1 Fault Code Chart after serial number 17407 5 3 Chart Number Chart Title 1 All Functions Will Not Operate 5 4 2 Pump Motor Will Not Operate Rev A ssssssssseseeeeeeeeneeeen nennen 5 6 3 All Functions Inoperative Power Unit Starts and Runs Rev 5 8 4 Ground Controls Inoperative Platform Controls Operate Normally Rev A 5 9 5 Platform Controls Inoper
19. Q 8 9 8 8 U6 motor rant 9 9 8 CONTROLLER FB l d ITN G6 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION 4 pu L p Tye 7 A X A X X 4 X 4 X X X e e L_4 L gt Li GND GND April 2003 Section 6 Schematics SSS Sa LLL Electrical Schematic from serial number 17408 to 21064 D B A REV M L K J H ple 3 BK POWER TO PLATFORM CONTROLS n lA gt A RD POWER TO GROUND CONTROLS 0 p B WH GROUND D 3 D BL DATA LINK HIGH E 3 E YL DATA LINK LOW ABBREVIATION LEGEND QD3 Item Description fa ee 1 5 Battery BN Button BN5 Horn Lift enable CB2 Circuit breaker 7A CR5 Horn relay with H2 option D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L19 Power L25 Fault LS Limit switch LS6 Platform up down L
20. WH RD ere WH A r 51 f BL B B DY CN KEY SWITCH t 1 1 BK 0 C m 39c OR E E JV 1 CB2 P1 I 7A EMERGENCY NC 4 NCHO CIRCUIT STOP BREAKER Ho D VY MULTI FUNCTION ALARM LS6 PS2 LS7 EE DOWN PLATFORM POTHOLE LIMIT SWITCH OVERLOAD GUARD PRESSURE SWITCH JB SWITCH 1 ORTON NCHO i GROUND 1 1 CONTROL PLATFORM Ai UP DOWN SWITCH SWITCH J S5 E s oc 30 86 I i CR5 A ry g amp 8 z 8 8 s 5 i z E 5 5 5 zg T 1 fes H2 OPTION 5 c 5 E x oOo FSS amp 4 3 I FRE 5 9 m m oim E P i i LEVEL 8 dg 2 2 E T a 02955 2 SENSOR 212 8 d 258 z 2 3 52526 g Seen ff 8 2 99 d m d cee om 75 m 3 s S m E I 46 E B e E 5 d o 5 5 U27 y ip 2 9 S7 47 mH E A i LEVEL INDUCTOR G 5 SENSOR NOISE 2 ee SUPPRESSION E zx BN _ B8 A8 A9 12 B12 C2 B9 Bt C12 A10 10 B2 A4 2 Ci Ci A5 OUT OUT OUT IN IN OUT IN IN IN IN IN OUT IN IN IN IN IN OUT ELECTRONIC CONTROL MODULE OUT OUT OUT OUT OUT OUT OUT OUT B3 c9 C7 B7 AT C6 B6 AG ul gt m ee ee m B FB 2 g 9 i 9 9 9 4 5 3 E E 2 g S s z 8
21. o z 30 86 5 4 o gt gt gt o o 4 J ra aoe g x 2 RE Q 9 2 z 292 55 2 985 H2 OPTION 9 E 2 c umg 5 E ES 6093s E E 9 3 5 9 22355 eo 2 0 m E 5 Q CoB ERR 2 amp 2 d 2 2 a amp 9 R21 519 Be 3 8 m d 22558 2 3 75 OHM ml G s 3 v Jj t azass 8 2 e o 5g EI U27 3 m 2 3 AR 47 mH 3 3 INDUCTOR m 5 m 5 QD1 9 NOISE 2 SUPPRESSION pes BN B8 A9 12 Bi2 C2 11 C12 A10 10 B2 A4 A2 Bi Ci Cii AS OUT OUT OUT IN IN OUT IN IN IN IN IN OUT IN IN IN IN IN OUT 1 OUT U5 6 ELECTRONIC CONTROL MODULE CHARGER OUT OUT OUT OUT OUT OUT OUT OUT B3 c9 C7 B7 AT C6 B6 A6 Mn meee ee AC INPUT Klay T T y FB ATAN 2 8 9 3 g D D le D j x i lt Q 7 F8 N r 8 8 8 8 8 E BOA FUSE U6 motor 3 P 1 MA F CONTROLLER FB EN i U13 G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION c L ic e I 8 e e e GND GND e L2 6 17 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics Electrical Schematic
22. 39 Center a lifting jack under the drive chassis at the ground controls side of the machine 40 Raise the machine approximately 2 inches 5 cm Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 41 Place a 0 85 x 6 x 6 inch 21 5 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 42 Lower the machine onto the blocks 43 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The tilt sensor alarm should sound 44 Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 45 Lower the platform to the stowed position 46 Raise the machine approximately 2 inches 5 cm 47 Remove the blocks from under both wheels 48 Lower the machine and remove the jack 49 Center a lifting jack under the drive chassis at the battery pack side of the machine 50 Raise the machine approximately 2 inches 5 cm 51 Place a 0 98 x 6 x 6 inch 25 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine 52 Lower the machine onto the blocks GROUND CONTROLS 53 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 1 m Result The tilt sensor alarm should sound O Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted
23. 9 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 10 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 11 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to step 20 12 Turn the key switch to the orr position and push in the red Emergency Stop button to the orF position at the ground controls 13 Tag and disconnect the wiring harness from the level sensor limit switch and alarm Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B GROUND CONTROLS 14 Remove the tilt level sensor box retaining Steer end fasteners Remove the tilt level sensor box from the machine 15 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level sensor box 0 16 Place the new tilt level sensor the tilt level sensor box with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Install the level sensor retaining fasteners ADANGER Tip over hazard The tilt level sensor must be insta
24. CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result If the platform does not stop or the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 54 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 55 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 56 Install the tilt level sensor box cover 57 Raise the platform slightly 58 Return the safety arm to the stowed position 59 Lower the platform to the stowed position 60 Raise the machine approximately 2 inches 5 cm 61 Remove the blocks from under both wheels 62 Lower the machine and remove the jack Part No 72876 Genie GS 1530 and GS 1930 4 45 Section 4 Repair Procedures April 2003 4 5 Tilt Level Sensor after serial number 50443 How to Install and Calibrate the 1 5 Level Sensor This procedure is for models equipped with a 1 5 side 3 front 3 rear level sensor Type Serial range GS 1530 Australia after 50443 GS 1930 ANSI CSA Austr
25. Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 59 Series parallel coil fault DIP switch settings are incorrect Troubleshoot and correct DIP switch settings 68 Low battery voltage Batteries discharged Charge batteries 88 ECM has been erased Static strap may be missing from the machine Replace static strap Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April 2003 Chart 1 All Functions Will Not Operate Be sure the circuit breaker and fuse are not tripped or blown Be sure both Emergency Stop Switches are pulled out to the on position Be sure the batteries are fully charged and properly connected Be sure the hydraulic tank is filled to the correct level With the key switch turned to platform control and both Emergency Stop buttons pulled out to the ON light is on position press and hold the function enable switch Visually inspect the power on LED light is not on After serial number bad 25141 Troubleshoot the CR48 power relay to U5 good Check voltage on the AN output side of the 275A fuse F6 20V or more Check continuity from the B terminal on the motor controller U6 to the negative battery cable at Q
26. N C H O Normally closed held open Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R15 5000 ohm potentiometer R21 75 ohm resistor Sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Valve coil Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up J H Fc BK POWER TO PLATFORM CONTROLS A A RD POWER TO GROUND CONTROLS a ic B B WH GROUND m D D BL DATA LINK HIGH E E YL DATA LINK LOW QD3 lE IA WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN Green OR Orange RD Red WH White YL Yellow DIP SWITCHES e gt 24V DC 8 D7 VOLTAGE U REGULATOR POUT1 Section 6 Schema
27. POUT8 BATTERY LEVELS 4 POUT9 La DRIVE LED L17 U3 POUT10 LIFT LED L16 PRINTED CIRCUIT BOARD PLATFORM CONTROLS MEMBRANE DECAL PANEL HIGH TORQUE BN6 HORN BN5 5 DRIVE ENABLE BN8 LIFT ENABLE BN9 POUT11 O H1 aarm PIN11 PLATFORM CONTROLLER 4 Part No 72876 Genie GS 1530 and GS 1930 6 20 April 2003 Section 6 Schematics SSeS Sey Electrical Schematic from serial number 25142 to 28936 Section 6 Schematics April 2003 E Electrical Schematic from serial number 28937 to 35799 REV C rapa 1 76F _78 WH RD c C c 7 WH A C A ss IKS1 CR48 E LL BL s B 3 a KEY SWITCH ecd i z POWER BK D D a a RELAY amp 85 e ole i TO U5 OR E E 1 ee o NN A ca am su CB2 P1 B er 7A EMERGENCY 2 EM d NJ PLATFORM CONTROL 1 39C i 1 1 dr N C 4 N O 1 i JB LS6 H5 PS2 157 D
28. Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 GROUND CONTROLS How to Install and Calibrate the 2 Level Sensor This procedure is for models equipped with a 2 side 3 front 5 rear level sensor Type Serial range GS 1530 ANSI CSA CE before 50444 GS 1530 Australia before 24998 GS 1930 ANSI CSA before 24998 GS 1930 CE before 50444 GS 1930 Australia before 48338 Tip over hazard Failure to install A DANGER or calibrate the tilt level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls REV B 3 Block the wheels at the non steer end of the machine 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm 6 Place a 0 91 x 6 x 6 inch 23 1 mm x 15 cm x 15 cm thick steel block under both wheels at the steer end of the machine 7 Lowerthe machine onto the blocks 8 Raise the platform 7 to 8 feet 2 1 to
29. Platform left turn switch fault Platform right turn switch fault Malfunctioning limit switch OR wire disconnected from limit switch Malfunctioning steer left microswitch Malfunctioning steer right microswitch Troubleshoot limit switch OR inspect wire connection Troubleshoot steer left microswitch Troubleshoot steer right microswitch 46 See Chart 5 Platform drive enable switch fault Malfunctioning drive enable switch Troubleshoot drive enable switch 47 52 See Chart 11 53 See Chart 12 Platform joystick fault Forward coil fault Reverse coil fault Joystick potentiometer not centered Malfunctioning coil OR wire disconnected from coil Malfunctioning coil OR wire disconnected from coil Verify potentiometer setting Troubleshoot coil OR inspect wire connection Troubleshoot coil OR inspect wire connection 54 See Chart 6 Up coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 55 See Chart 7 Down coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 56 See Chart 9 Steer right coil fault Malfunctioning coil OR wire disconnected from coil Troubleshoot coil OR inspect wire connection 57 See Chart 8 58 See Chart 10 or Chart 10A Steer left coil fault Brake coil fault
30. dex CB2 P1 B 4 7A EMERGENCY CIRCUIT STOP 2 BREAKER i PLATFORM CONTROL 1 i 39C lr lt N C 4 NO 14 4 i ea B 1 te 56 H5 PS2 LS7 GROUND DOWN ALARM PLATFORM POTHOLE 1 CONTROL LIMIT OVERLOAD GUARD 21B age CDD ARE SWITCH PRESSURE SWITCH 3 TS66 SWITCH PLATFORM OPTION N C H O UP DOWN SWITCH 8 5 158 3 POTHOLE GUARD SWITCH i jj CR5 gt gt gm o m m S 4 x HORN RELAY 8 6 R 2 iS 2 5 9 56343 zo Rd e 87 H2 OPTION 5 8 5 o 5 b gt gt E 919 9 DA E Q D 2 5 0 2 a 9 z o m 29 9 9 lt gt Qo RR Q 2 SENSOR E d o S28 97 CIRCUIT R21 3 g 2 2 Z 2 f amp D 3 BOARD 2 2 D 75 OHM 9 3 2 E Q GS Bi 5 ji 9 5 1 027 2 E S7 47 mH B m i LEVEL INDUCTOR SENSOR 9 NOE g icc op SENSOR 5 SUPPRESSION aH EN F6 275A FUSE a pa a LL B8 A9 A12 B12 11 612 B9 A10 B10 C2 A4 B11 A2 B1 C1 Ch A5 OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT a1 our U5 6 U9 ELECTRONIC CONTROL MODULE CHARGER OUT OUT OUT OUT OUT OUT OUT B3 C7 B7 A7 C6 B6 A6 Se _ _ _ e M M M MM meee eee ee AC INPUT
31. 11 C12 B9 A10 B10 C2 B1 A4 A2 Bi Ci Cii A5 OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT U5 U9 A1 OUT ELECTRONIC CONTROL MODULE BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT B3 C7 B7 A7 C6 B6 Lr ac INPUT x ST TT CT 2 B 2 9 E 3 2 2 eL Q 4 lt 2 Q F8 8 8 8 8 F ei 50A FUSE U6 motor ta V P CONTROLLER FB TW AT U13 G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8 l HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION i i n 1 mtt X X A X A X A X X __ L _ GND GND 6 27 Genie GS 1530 and GS 1930 Part No 72876 REV B BK RD H POWER TO PLATFORM CONTROLS April 2003 Section 6 Schematics T Electrical Schematic from serial number 49805 to 51014 POWER TO GROUND CONTROLS WH ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay Horn relay with H2 option CR48 Power relay to 05 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons Gauge G6
32. April 2003 Section 4 Repair Procedures REV B FUNCTION MANIFOLD Part No 72876 Genie GS 1530 and GS 1930 4 59 Section 4 Repair Procedures April 2003 FUNCTION MANIFOLD 6 3 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Be sure that the hydraulic oil level is between the FULL and ADD marks on the oil level indicator decal Before serial number 35800 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold item AC 2 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications 3 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls REV B 5 Hold the system relief valve with a wrench and remove the cap item AC AA lt AB e NS amp ay z i e a system relief valve b function manifold 6 Models with lift function enable button Press and hold the lift function enable button Models with drive function select button Press the lift function select button 7 Press and hold the function enable switch 8 While activating the platform u
33. Genie Service Manual refer to inside cover for serial number information Part No 72876 September 2006 Rev C2 GS 1530 GS 1930 Introduction April 2003 Important Read understand and obey the safety rules and operating instructions in the Genie GS 1530 and GS 1930 Operator s Manual before attempting any maintenance or repair procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us PO Box 97030 Redmond WA 98073 9730 USA www genieindustries com e mail te
34. Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall when the rod end pivot pin is removed if not properly supported 24 Lower the cylinder onto the number 1 center pivot pin index 10 25 Remove the cables from the number 3 inner arm index 17 and lay them to the side 26 Attach a lifting strap from an overhead crane to the number 3 inner arm index 17 27 Remove the external snap rings from the number 3 pivot pin index 6 at the steer end Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 28 Use a soft metal drift to remove the number 3 pivot pin index 6 Remove the number 3 inner arm index 17 from the machine Bodily injury hazard The number ACAUTION 3 inner arm index 17 may become unbalanced and fall if not properly supported when it is removed from the machine 29 Remove the cables from the lower cable tray and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 30 Remove the mounting fasteners from the lower cable tray supports 31 Remove the mounting fasteners from the lower cable tray mounting bracket on the number 2 center pivot pin index 7 at the ground controls side of the machine 32 Slide the cable tray towards the battery pack side of the machine and remove it from the machine 33 Attach a lifting strap from an overhead cr
35. jerking and unusual noise over the entire proportionally controlled speed range Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position 4 Models with drive function select button Press the drive function select button so Genie a drive function select button BN8 REVC Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Section 2 Specifications 3 14 Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures REV B 8 Test the Drive Speed Raised Position Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over
36. 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
37. 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device 4 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Raise the platform 6 to 7 feet 1 8 to 2 1 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 7 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Mark the mounting position of the level sensor box on the drive chassis 9 Remove the level sensor box cover 4 22 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 10 Mark the mounting position of the level sensor on the level sensor box 11 Remove the level sensor box mounting fasteners and slide the box towards the non steer end of the machine as far as it can go Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch level sensor or wiring while moving the level sensor box 12 Secure the ends of the scissor arms together at both end
38. 20V or more Disconnect the wires from the coil on the steer left directional valve on the function manifold item AF or Bl and check the resistance of the valve coil See Repair Section 0 or infinite ohms Replace the steer left directional valve coil item AF or BI Check continuity of the steer left right microswitch SW6 inside the joystick controller handle JC1 good Repair or replace the wire circuit from SW6 to the platform controls circuit board U3 OR replace U3 OR consult the Genie Industries Service Department Chart 8 Repair open in the WH B7 left coil wire from the coil on the steer left directional valve item AF or BI to the ECM U5 OV OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Repair or replace the 25 to 27 steer directional valve ohms cartridge item AF or BI OR consult the Genie Industries Service Department bad Replace SW6 Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April 2003 CHART 8 previous page Continued from the REVA Remove the mechanical restrictions Install a 0 to 2000 psi Are there mechanical 138 bar pressure restrictions keeping the gauge at the quick steer left function from disconnect coupling on moving the function manifold and activate the steer
39. ACAUTION clear of moving parts when lowering the arms onto the block 53 Remove the cables and hydraulic hoses from the number 1 inner arm index 11 and lay them to the side Component damage hazard CAUTION Cables and hoses can be damaged if they are kinked or pinched SCISSOR COMPONENTS 54 Support and secure the entry ladder to an appropriate lifting device 55 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device 56 Attach a lifting strap from an overhead crane to the number 1 outer arm index 24 Do not apply any lifting pressure 57 Remove the external snap rings from the number 1 center pivot pin index 10 58 Use a soft metal drift to remove the number 1 center pivot pin index 10 Bodily injury hazard The number A CAUTION 1 outer arm index 424 may become unbalanced and fall if not properly supported when the pin is removed 59 Slide the number 1 outer arm index 24 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm index 424 may become unbalanced and fall if not properly supported when it is removed from the machine Note the position of the wear pads before the arm is removed so when the scissor is assembled they will be in the correct position Part No
40. B3 ECM ground output B3 ECM ground output B4 Spare B4 Spare B5 Spare B5 Spare B6 Platform down coil Y7 output B6 Platform down coil Y7 output B7 Steer left coil Y4 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B9 Multi function alarm H5 output B10 Pothole limit switch input B10 Pothole limit switch input B11 Drive enable power input B11 Drive enable power input B12 Platform up TS66 input C11 Level sensor signal S7 input Down limit switch LS6 input C1 Platform data link input C1 Platform data link input Yellow wire at platform Yellow wire at platform C2 Key switch to ground control input C2 Power to ECM input C3 Spare C3 Spare C4 Spare C4 Spare C5 Spare C5 Spare Drive forward coil Y6 output Drive forward coil Y6 output C7 Steer right coil output C7 Steer right coil output C8 Spare C8 Spare C9 Brake release coil Y2 output C9 Brake release coil Y2 output C10 Spare C10 Spare C11 Level sensor signal S7 input Down limit switch LS6 input Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics REV B ECM PIN OUT LEGEND CG 2
41. FB 2 9 E K g o m E 2 m 2 uU l 8 2 E z 8 a Q 7 F8 U6 Vly 8 50A FUSE MOTOR 3 1 l CONTROLLER LL U13 G6 2 FB H2 Y3 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION i e L Le f Le 8 GND GND 6 23 Genie GS 1530 and GS 1930 Part No 72876 REV lt April 2003 ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay Horn relay with H2 option CR48 Power relay to 05 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons Gauge G6 Hour meter G7 Battery charge indicator GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole 5 Hydraulic power unit N C Normally closed
42. Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA Steer Left Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON light is position on Models with lift function enable button activate the function enable switch and activate the steer rocker switch in the LEFT direction and check to see if the error indicator light at the platform controls is on Models with drive function select button press the drive function select button and activate the function enable switch and activate the steer rocker Switch in the LEFT direction and check to see if the error indicator light at the platform controls is on light is not on Activate the function enable switch and activate the steer left function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the WH C7 rt coil wire terminal at the steer right directional valve coil item AF or Bl without disconnecting the wire and the negative lead of the volt meter to the brown ground wire at the valve coil Activate the steer rocker switch in the RIGHT direction and check the voltage
43. Group T 105 Quantity 8 Battery capacity maximum 225AH Reserve capacity 25A rate 447 minutes Fluid capacities Hydraulic tank 5 gallons 18 9 liters Hydraulic system including tank 5 5 gallons 20 8 liters Tires and wheels Tire size solid rubber 12 x 4 5 x 8 6 in 30 5 x 11 4 x 21 8 cm Tire contact area 9 sq in 58 sq cm Overall tire diameter 12 in 30 5 cm Wheel diameter 8 6 in 21 8 cm Wheel width 4 5 in 11 4 cm Castle nut torque dry 300 ft lbs 406 7 Nm Castle nut torque lubricated 225 ft lbs 305 Nm For operational specifications refer to the Operators Manual REVC Performance Specifications GS 1930 Drive speed maximum Platform stowed 2 5 mph 40 ft 10 7 sec 4 km h 12 2 m 10 7 sec Platform raised 0 5 mph 40 ft 55 sec 0 7 km h 12 2 55 sec Braking distance maximum High range on paved surface 2 ft 61 cm Load capacity maximum Platform retracted 500 Ibs 227 kg Platform only 250 Ibs 113 kg Extension only 250 Ibs 113 kg Function speed maximum from platform controls with 1 person in platform 15 to 17 seconds 22 to 24 seconds Platform up Platform down Airborne noise emissions 70 dB Maximum sound level at normal operation workstations A weighted Gradeability ANSI CSA CE 3096 Australia 2596 Continuous improvement of our products is a Genie policy Product specifications are subject to change without no
44. LAL MOIOCLL 55 1S 2 366 1 Co x ECM PIN OUT LEGEND From serial number 25142 to 35799 ECM PIN OUT LEGEND From serial number 35799 to 59999 Item Description Item Description A1 Flashing beacon FB1 output A1 Flashing beacon FB1 output A2 Ground from platform controls input A2 Ground from platform controls input Blue wire at platform Blue wire at platform Spare Spare A4 Power from platform controls to ECM input A4 Power from platform controls to ECM input White wire at platform White wire at platform A5 Level sensor power S7 output A5 Level sensor power S7 output A6 Platform up coil Y8 output A6 Platform up coil Y8 output A7 Drive reverse coil Y5 output A7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 output A8 Motor controller U6 terminal 1 A9 Motor controller U6 terminal 3 output A9 Motor controller U6 terminal 3 A10 Overload sensor PS2 input A10 Overload sensor PS2 input A11 Key switch to platform control input A11 Key switch to platform control input A12 Platform down TS66 input A12 Platform down TS66 input B1 Platform data link input B1 Platform data link input Black wire at platform Black wire at platform B2 Spare B2 Spare B3 ECM ground output B3 ECM ground o
45. Press and hold the lift function enable button and activate the controller in the DOWN direction and check the voltage Models with drive function select button Press the lift function select button and activate the controller in the DOWN direction and check the voltage 20V or more 0 or infinite ohms Label and disconnect the wires from the coil on the platform lowering valve item D at the platform lift cylinder and check the resistance See Repair Section 23 to 25 ohms With the platform raised platform and the safety arm lowers removed pull the manual platform lowering handle at the ground controls platform does not lower Are there mechanical restrictions keeping the platform from lowering no yes Remove mechanical restrictions keeping the platform from lowering REVA Repair open in the WH B6 down coil wire from the platform lowering valve coil item D to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the battery module tray OR replace U5 OR consult the Genie Industries Service Department Replace platform lowering valve coil item D Repair or replace the platform lowering valve cartridge item D Repair or replace the platform lowering valve cartridge item D OR repair or replace the lift cylinder OR replace the orifice or orifice washer item E OR consult the Genie Industries Service Department 5 12
46. make _ a second mark with a permanent ink marker to JIC 37 fittings indicate the proper tightening position 1 Align the tube flare hex nut against the nose of Use the JIC 37 Fittings table on the fitting body body hex fitting and tighten the the previous page to determine the hex nut to the body hex fitting to hand tight correct number of flats for the approximately 30 in lbs 3 4 Nm propertightening position 2 Make a reference mark on one of the flats of the The marks indicate that the correct hex nut and continue it on to the body hex tightening positions have been fitting with a permanent ink marker determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened a 2 y TI oe hydraulic hose hex nut reference mark body hex fitting a body hex fitting b reference mark second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Part No 72876 Genie GS 1530 and GS 1930 2 7 Section 2 Specifications April 2003 SPECIFICATIONS REVC Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose en
47. pressure more gauge at the quick disconnect coupling item AA or BA on the function manifold and activate the platform up function less than 3000 PSI Adjust the system relief valve item AC or BC OR repair or replace the platform lift cylinder OR the platform lowering valve item D may be stuck open OR the function manifold could have an internal defect Consult the Genie Industries Service Department Connect the positive lead from a volt meter to the coil on the platform up directional valve item AG or BG wire terminal without disconnecting the wire and the negative lead of the volt meter to the ground point on the manifold Activate the controller in the uP direction and check the voltage 20V or more 0 or infinite Disconnect the wire ohms from the platform up directional valve coil on the function manifold item AG or BG and check the resistance See Repair Section 18 20 ohms Repair or replace the platform up directional valve cartridge item AG or BG OR consult the Genie Industries Service Department Are there mechanical restrictions keeping yes platform up function from moving no Repair or replace the platform lift cylinder OR consult the Genie Industries Service Department Chart 6 Repair open in the WH A6 up coil wire from the platform up directional valve coil item AG or BG to the ECM U5 see Repair Section OR replace U5 OR consult t
48. properly supported when it is removed from the machine 23 Attach a lifting strap from an overhead crane to the number 2 inner arm index 6 24 Remove the external snap rings from the number 2 pivot pin index 7 25 Use a soft metal drift to remove the number 2 pivot pin index 7 Remove the number 2 inner arm index 6 from the machine Bodily injury hazard The number ACAUTION 2 inner arm index 6 may become unbalanced and fall if not properly supported when it is removed from the machine 26 Remove the safety arm from the number 2 inner arm index 6 that was just removed 27 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 28 Raise the number 1 inner arm index 9 approximately 2 feet 0 6 m and insert the safety arm between the number 1 inner arm index 49 and the number 1 outer arm index 19 Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the scissor arms onto the safety arm 29 Tag disconnect and plug the hydraulic hose on the lift cylinder index 15 Cap the fitting on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 30 Tag and disconnect the wi
49. z J d S gt 8 z g T 9i t E a lig PB amp 2 x 57 E D 3 LEVEL 5 QD1 9 m g E it Ll r r BN F6 s 275A FUSE D1 is I Sr B8 A8 A9 A12 B12 11 c12 B9 A10 B10 C2 B11 A4 A2 Bi Ci C11 A5 OUT OUT OUT IN N IN IN OUT IN IN IN IN IN IN IN IN IN OUT 1 U5 6 U9 A1 OUT ELECTRONIC CONTROL MODULE CHARGER OUT OUT OUT OUT OUT OUT OUT 5 T B3 C7 B7 A7 C6 B6 AG dou AC INPUT B O Vo de x a BATTERY FB Iz CAE ATA 9 9 g z g g 3 3 E 5 m 5 7 CE F8 SI 8 8 5 8 ee eee ae 50A FUSE U6 motor E d CONTROLLER FB Te __ _ __ TERES 1013 G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8 1 HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP 3 OPTION OPTION OPTION OPTION n 4 n t bs X X X A X X X 8 leet on L_ L_ L_ L_ GND GND gt 6 29 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics SSS a SSS ae Electrical Schematic from serial number 51015 to 52966 REV B M L K N
50. 0 75 gpm 2 8 L min AB ones Steer circuit 3 Relief valve 3500 psi 241 3 bar AC System relief 4 Orifice washer 0 040 in 1 mm Steer circuit 5 Relief valve 1500 psi 103 4 bar Steer relief 6 Solenoid valve 3 position 4 way AP unis Steer left right 7 Solenoid valve 2 position 4 way TAN E E Platform up 8 Solenoid valve 2 position 2 way O AH Brake 9 Solenoid valve 3 position 4 way AIL seilicet Drive forward reverse 10 Check valve 5 psi 0 3 bar Brake 11 Check valve 5 psi 0 3 bar Steer circuit Torque 35 ft lbs 47 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 4 56 Genie 95 1530 69 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B FUNCTION MANIFOLD AK DM Part No 72876 Genie GS 1530 and GS 1930 4 57 Section 4 Repair Procedures April 200
51. 1930 Part No 72876 April 2003 Section 6 Schematics REV A Platform Controls Wiring Diagram from serial number 51015 to 59999 P2 EMERGENCY STOP UTTON S c e L a5 ON SW25 DIP SWITCH GO NC g s BN U3 PLATFORM CONTROLS ct GN CIRCUIT BOARD IE WH tJ _1 i RD BK im OR o 2597 PP etsy i ses E p Q S JC1 JOYSTICK CONTROLLER G9 Q G9 erre GO m rf YL BL WH BK RD rano TO COIL CORD ASSEMBLY ZN v H1 ALARM WIRE COLOR LEGEND Color Description BL Blue BK Black ABBREVIATION LEGEND BN Brown Item Description QGren H1 Alarm Sy JC1 Joystick controller BUE P2 Emergency Stop button at platform controls RD Red SW25 DIP switch WH White U3 Platform controls circuit board YL Yellow Part No 72876 Genie GS 1530 and GS 1930 6 9 Section 6 Schematics April 2003 Ground Controls Wiring Diagram REV Ground Controls after serial number 52966
52. 2 4 m 9 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 10 Lower the scissor arms onto the safety arm Crushing hazard Keep hands AWARNING clear of the safety arm when lowering the platform 11 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to step 20 12 Turn the key switch to the orr position and push in the red Emergency Stop button to the orF position at the ground controls 13 Tag and disconnect the wiring harness from the level sensor limit switch and alarm Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B GROUND CONTROLS 14 Remove the tilt level sensor box retaining Steer end fasteners Remove the tilt level sensor box from the machine 15 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level i E sensor box 0 16 Place the new tilt level sensor the tilt level sensor box with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor 2 base closest to the short side of the tilt level sensor box ADANGER Tip over hazard The tilt level sensor must be installed with the X on the level sensor base close
53. 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS 60 Attach the strap from an overhead crane to the number 1 inner arm index 11 Do not lift it 61 Remove the pin retaining fasteners from both of the number 1 pivot pins index 12 at the steer end of the machine Use a slide hammer to remove the pins 62 Remove the number 1 inner arm index 11 from the machine Bodily injury hazard The number ACAUTION 1 inner arm index 11 may become unbalanced and fall if not properly supported when it is removed from the machine Component damage hazard Be sure not to damage the limit switch or level sensor box components when the number 1 inner arm index 11 is removed from the machine CAUTION REVA How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Support and secure the entry ladder to an appropriate lifting device 4 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if not properly supported and secured to the lifting device Raise the platform 6 to 7 feet 1 8 to 2 1 m Lift th
54. AS Co x ECM PIN OUT LEGEND From serial number 21065 to 25141 12 Platform down TS66 input Item Description Item Description A1 Spare A1 Flashing beacon FB1 output A2 Ground from platform controls input A2 Ground from platform controls input White wire at platform White wire at platform Spare A3 Spare A4 Power from platform controls to ECM input A4 Power from platform controls to ECM input Red wire at platform Red wire at platform 5 Level sensor power S7 output A5 Level sensor power S7 output A6 Platform up coil Y8 output A6 Platform up coil Y8 output 7 Drive reverse coil 5 output A7 Drive reverse coil Y5 output A8 Motor controller U6 terminal 1 output A8 Motor controller U6 terminal 1 output A9 Motor controller U6 terminal 3 output A9 Motor controller U6 terminal 3 output A10 Overload sensor PS2 input A10 Overload sensor PS2 input 11 Key switch to platform control input 11 Key switch to platform control input 12 Platform down TS66 input B12 Platform up at ground controls TS66 input B1 Platform data link input B1 Platform data link input Blue wire at platform Blue wire at platform B2 Power to platform controls output B2 Power to platform controls output Black wire at platform Black wire at platform
55. FORWARD DOWN UP E SEa OPTION OPTION OPTION OPTION aa i i i i 4 8 jel L_ e Li gt GND GND 6 19 Genie GS 1530 and GS 1930 Part No 72876 REV BK RD H POWER TO PLATFORM CONTROLS April 2003 Section 6 Schematics E Electrical Schematic from serial number 25142 to 28936 E D C B A POWER TO GROUND CONTROLS WH ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay Horn relay with H2 option CR48 Power relay to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons Gauge G6 Hour meter G7 Battery charge indicator GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole 5 Motor N C Normally closed N C H O Normally closed held open Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform contr
56. Green OR Orange RD Red WH White YL Yellow GROUND DATA LINK HIGH DATA LINK LOW 9 9 SW25 DIP SWITCHES lt e 24V DC 07 VOLTAGE U J REGULATOR POUT1 D 1 JC Joystick CONTROLLER WHNL 5000 OHM SW 6steer POTENTIOMETER e 2 SW5 FUNCTION 3 POWER LED L19 POUT2 FAULT LED L25 POUTS POUT4 BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 POUT7 4 BATTERY LEVEL3 gt 37 BATTERY 4 POUT8 POUT9 BATTERY LEVEL 5 4 DRIVE LED L17 POUT6 POUT10 Sa LIFT LED L16 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD PLATFORM CONTROLS MEMBRANE DECAL PANEL HIGH TORQUE BN6 HORN BN5 5 DRIVE ENABLE BN8 LIFT ENABLE BN9 POUT11 O PIN11 H1 aarm PLATFORM CONTROLLER i Part No 72876 Genie GS 1530 and GS 1930 6 26 April 2003 Section 6 Schematics SSH SSS Sey Electrical Schematic from serial number 40926 to 49804 Section 6 Schematics b April 2003
57. Hour meter G7 Battery charge indicator GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole 5 Hydraulic power unit N C Normally closed N C H O Normally closed held open Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R15 5000 ohm potentiometer R21 75 ohm resistor Sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch Electronic component AS BL OR U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression WIRE COLOR LEGEND Color Description BL Blue Valve coil BK Black Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8
58. IC3645SE6B300GN1 1 ies Inductor noise suppression 47 mH 2 5A 0 034 ohm 47124 3 47 15 1 Coil 20V DC with diode 39347 Hydra Power Systems 6309757 tius 1 Y4 uus Coil 20V DC with diode before serial number 35800 39347 Hydra Power Systems 6309757 isses 2 after serial number 35799 52594 Hydra Power Systems 6309820 2 Y5 Y6 Y8 Coil 20V DC with diode before serial number 35800 44176 Hydra Power Systems 6359752 edere 3 after serial number 35799 52595 Hydra Power Systems 6359792 ats 3 VT oes ctn Coil 20V DC before serial number 23568 44787 Hydra Power Systems 10166 25 1 es 1 DEP ET Coil 20V DC with diode after serial number 23567 66467 Hydra Power Systems 10188 91 1 Part No 72876 Genie GS 1530 and GS 1930 6 3 Section 6 Schematics April 2003 ECM Pin out Legend ECM PIN OUT LEGEND From serial number 17408 to 21064 REV Ci a e 000000000 1009 T CAS MOIOCLL 55
59. JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline button BN6 e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 Use the steering thumb rocker switch on the joystick to increase or decrease the stowed drive speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position 4 8 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B How to Adjust the Raised Drive Speed ADANGER ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Software revision AO and BO 1 Push the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls 3 PLATFORM CONTROLS Press and hold the lift function enable and horn buttons and turn the key switch to pl
60. Platform up BN Brown GN Green OR Orange RD Red WH White YL Yellow GROUND DATA LINK HIGH DATA LINK LOW SW25 DIP SWITCHES 24V VOLTA REGULAT U3 PRINTED CIRCUIT BOARD P2 EMERGENCY STOP JC 1 Joystick CONTROLLER 1 WHNL 2 gs R15 x 5000 OHM Fr POTENTIOMETER 6 2 7 SW5 8 FUNCTION DC 8 D7 uju GE OR POUTI POWER LED L19 3 POUT2 c L 4 FAULT LED L25 POUT3 HIGH TORQUE LED L21 POUT4 4 BATTERY LEVEL 1 POUTS BATTERY LEVEL2 POUT6 L 4 BATTERY LEVEL3 gt 37 POUT7 1 4 BATTERY LEVEL 4 POUT8 4 BATTERY LEVELS 4 POUT9 1 4 DRIVE LED L17 POUT10 L 4 LIFT LED L16 5 PLATFORM CONTROLS PLATFORM CONTROLS MEMBRANE DECAL PANEL 4 HIGH TORQUE BN6 4 HORN BN5 5 4 DRIVE ENABLE BN8 LIFT ENABLE BN9 POUT11 H1 ALARM PLATFORM CONTROLLER j Part No 72876 Genie GS 1530 and GS 1930 6 28 April 2003 Section 6 Schematics ed Electrical Schematic from serial number 49805 to 51014 Section 6 Schematics April 2003 jm Electrical Schematic REVB from serial number 51015 to 52966
61. and tighten the fasteners Component damage hazard The CAUTION connectors on the motor controller will short to ground if the motor controller mounting bracket is not installed before the battery pack is connected REV B 16 Install the hydraulic pump return hose onto the fitting at the top of the hydraulic tank and tighten the hose clamp 17 Fill the tank with hydraulic oil until the fluid is within the FULL and App marks on the oil level indicator decal Do not overfill 18 Activate the pump to fill the hydraulic system with oil and bleed the system of air and check for leaks Component damage hazard The CAUTION pump can be damaged if operated without oil Be careful not to empty the hydraulic tank while in the process of filling the hydraulic system 19 Repeat steps 17 through 18 until the hydraulic System and tank are both full 20 Clean up any oil that may have spilled Properly discard the used oil and filter Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the Genie GS 1530 and GS
62. at the steer end of the machine 4 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap item BC 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure ADANGER Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap 11 Repeat steps 5 through 7 to confirm the relief valve pressure Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 FUNCTION MANIFOLD How to Adjust the Platform Lift Relief Valve after serial number 35799 Be sure that the hydraulic oil level is between the full and add marks on the oil level indicator decal 1 Open the hydraulic power unit module tray and locate the s
63. drive chassis 21 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 22 Install the new wear pad 23 Slide the scissor assembly back into the drive chassis 24 Lower the scissor assembly into position and install the pivot pins Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while installing the scissor assembly Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS O 5 REVA ORO 1 9 OJQ N 2 98 1930 Steer End S Non steer End 22 N ER Number 5 pivot pin steer end Number 4 center pivot pin Number 4 pivot pin steer end Number 3 outer arm Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin 2 pins Lift cylinder 9 Number 2 pivot pin steer end 10 Number 1 center pivot pin 11 Number 1 inner arm 12 Number 1 pivot pin steer end 2 pins 13 Number 5 pivot pin non steer end 14 Number 4 inner arm 15 Number 4 outer arm 16 Number 4 pivot pin non steer end 17 Number 3 inner arm 18 Number 3 center pivot pin 19 Nu
64. from the wheels at the steer end of the machine 39 Center a lifting jack under the drive chassis at the ground controls side of the machine 40 Raise the machine approximately 2 inches 5 cm Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 41 GS 1530 and GS 1930 Place a 0 62 x 6 x 6 inch 15 7 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 1932 Place a 0 82 x 6 x 6 inch 17 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 42 Lower the machine onto the blocks 43 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound 44 Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 45 Lower the platform to the stowed position 46 Raise the machine approximately 2 inches 5 cm 47 Remove the blocks from under both wheels 48 Lower the machine and remove the jack 49 Center a lifting jack under the drive chassis at the battery pack side of the machine 50 Raise the machine approximately 2 inches 5 cm 51 GS 1530 and GS 1930 Place a 0 76 x6 x6 inch 19 3 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the machine GS 1932 Place a 0 82 x 6 x 6 inch 20 8 mm x 15 cm x 15 cm thick steel block under both wheels at the battery pack side of the m
65. left function Repair or replace the steer cylinder OR consult the Genie less than Industries Service 1500 PSI Department Reset the steer relief Repair or replace the valve pressure steer cylinder OR item AE or BF replace the steer left See Repair Section right valve cartridge item AF or BI OR the less than function manifold could 1500 PSI have an internal defect Consult the Genie Replace the steer relief Industries Service valve item AE or BF Department 5 14 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA Steer Right Function inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON light is position on Models with lift function enable button activate the function enable switch and activate the steer rocker switch in the RIGHT direction and check to see if the error indicator light at the platform controls is on Models with drive function select button press the drive function select button and activate the function enable switch and activate the steer rocker switch in the RIGHT direction and check to see if the error indicator light at the platform controls is on light i
66. onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 35 Install the tilt level sensor box cover 36 Raise the platform 7 to 8 feet 2 1 to 2 4 m 37 Return the safety arm to the stowed position 38 Lower the platform to the stowed position 39 Raise the machine approximately 2 inches 5 cm 40 Remove the blocks from under both wheels 41 Lower the machine and remove the jack Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 How to Install and Calibrate the 2 Level Sensor This procedure is for models equipped with a 2 side 3 front 3 rear level sensor Type Serial range GS 1530 ANSI CSA CE after 50443 GS 1930 CE after 50443 ADANGER Tip over hazard Failure to install or calibrate the tilt level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the cent
67. ov Section 5 Troubleshooting Flow Charts _ LLL Repair open in wire from the input side of P1 to circuit breaker CB2 OR reset or replace CB2 OR repair open in the wire from CB2 to QD1 Repair open in the wire from P1 to KS1 OR repair open in the wire jumper to each contact OR replace contact on P1 OR replace P1 Check the cam on KS1 bad good Replace contact OR refer to Platform Controls Inoperative Chart 6 OR consult the Genie Industries Service Department Check the cam on KS1 bad good Replace contact OR refer to Ground Controls Inoperative Chart 5 OR consult the Genie Industries Service Department CHART 1 Repair or replace KS1 Repair or replace KS1 Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April2003 Chart 2 Pump Motor Will Not Operate Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to ground controls and both Emergency Stop buttons pulled out to the position activate the lift function and check for voltage on the positive terminal D1 at pump motor M5 oV After serial number 25141 Troubleshoot the CR48 power relay to U5 good Check voltage on the B terminal at motor controller U6 Check for continuity in the positive cable circuit from the B terminal a
68. plug 20V or more Replace the coil cord assembly OR replace the platform controls Repair or replace the wire between P2 and U3 April 2003 REVA Before serial number 25142 Replace U5 After serial number 25141 Troubleshoot CR48 Repair or replace the disconnect plug R replace the harness pigtail Repair or replace the quick disconnect plug OR replace the control cable 5 24 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 5 Troubleshooting Flow Charts REVA CHART 16 owes DIP SWITCH P2 EMERGENCY STOP BUTTON Dr eh D L JC1 JOYSTICK U3 CONTROLLER PLATFORM CONTROLS CIRCUIT T BOARD e y Platform controls circuit board __ voltage regulator terminal 2 _ voltage regulator terminal 1 Bu circuit board voltage regulator voltage regulator terminal 3 Part No 72876 Genie GS 1530 and GS 1930 5 25 Section 5 Troubleshooting Flow Charts April 2003 CHART 16 Check for voltage at terminal 3 of the voltage regulator on U3 Replace U3 Continued from page 26 Check for continuity in Check for continuity in 41 Consult the Genie the blue data line the green data line or Industries Service from pin D of t
69. serious injury Select a test area that is firm level and free of obstructions How to Determine the Revision Level 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine 3 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls PLATFORM CONTROLS 4 Press and hold the lift function enable button OR press the lift function select button Genie a yellow arrow b joystick controller JC1 c lift function select button BN9 d red Emergency Stop button P2 e lift function enable button BN9 Slowly move the joystick in the direction indicated by the yellow arrow Result The software revision level will appear in the diagnostic display Result If the software revision level does not appear in the diagnostic display turn the key Switch to ground control and repeat steps 4 and 5 The software revision level will appear in the diagnostic display Push the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Part No 72876 Genie GS 1530 and GS 1930 4 5 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS How to Adjust the Lift Speed A DANGER Tip ove
70. the fitting CAUTION Component damage hazard and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Disconnect and plug the high pressure hydraulic hose from the hydraulic pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow There is no relief valve in the hydraulic pump and the pump can be damaged if the pressure is allowed to exceed 3200 psi 221 bar When testing the pump activate the pump in one second intervals until 3200 psi 221 bar is confirmed Do not over pressurize the pump 5 Remove the pressure gauge and reconnect the hydraulic hose the oil pressure to dissipate ilv ini i AWARNING Bodily injury hazard Spraying gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the high pressure port on the pump 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 54 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B HYDRAULIC PUMP How to Remove the
71. the level sensor box limit switch or level sensor while moving the scissor assembly 17 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis SCISSOR COMPONENTS 18 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 19 Install the new wear pad 20 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 21 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 22 Install the new wear pad 23 Slide the scissor assembly back into the drive chassis 24 Lower the scissor assembly into position and install the pivot pins CAUTION Component damage hazard Be careful not to damage the level sensor box limit switch or level sensor while installing the scissor assembly Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures Ap
72. to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect Control cable to ground QD4 Control cable to platform R21 75 ohm resistor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch U Electronic component WIRE COLOR U3 Encoder printed circuit board LEGEN D U5 Electronic control module in U6 Motor controller Color Description BL Blue U9 Battery charger BK Black U13 Voltage inverter option U27 47 mH inductor noise suppression BN Brown Y Valve coil GN Green Y3 Steer right GY Gray Y4 Steer left OR Orange Y5 Drive reverse PP Purple Y6 Drive forward RD Red Y7 Platform down WH White Y8 Platform up YL Yellow
73. tpa i ten eta task Eae eua tud e eek 6 2 ECM Pin out Legend Rev B sssssssssssseeeeeeeeenneeeennn nennen nennen nns 6 4 Control Relay Layout Rev A ssssssssssssssssseseee eene nnne enne enne 6 6 Platform Controls Wiring Diagram from serial number 17408 to 51014 Rev 6 8 Platform Controls Wiring Diagram from serial number 51015 to 59999 Rev A 6 9 Ground Controls Wiring Diagram Rev C 6 10 Level Sensor Box Wiring Diagram Rev A ssssssssseeeeene enm 6 11 Electrical Symbols Legend Rev 6 12 Electrical Schematic from serial number 17408 to 21064 Rev 6 13 Electrical Schematic from serial number 21065 to 21262 Rev 6 15 Electrical Schematic from serial number 21263 to 25141 Rev C 6 17 Electrical Schematic from serial number 25142 to 28936 Rev 6 19 Electrical Schematic from serial number 28937 to 35799 Rev 6 21 Electrical Schematic from serial number 35800 to 40925 Rev
74. years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING O 2n9e sed to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operatio
75. 0 O POUT11 PIN11 E D B A 1 JC Joystick CONTROLLER WHNL 5000 OHM SW6steer POTENTIOMETER PIS SW5 2 FUNCTION ENABLE POUTI POWER LED L19 3 POUT3 HIGH TORQUE LED L21 POUT4 BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 POUT6 BATTERY LEVEL3 gt 37 POUT7 BATTERY LEVEL4 POUTS BATTERY LEVELS 4 LIFT LED L16 PLATFORM CONTROLS MEMBRANE DECAL PANEL HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 5 LIFT ENABLE BN9 6 PLATFORM CONTROLLER 7 8 Part No 72876 Genie GS 1530 and GS 1930 6 22 April 2003 Section 6 Schematics es Electrical Schematic from serial number 28937 to 35799 Section 6 Schematics April 2003 E Electrical Schematic REVC from serial number 35800 to 40925 rapa 76F _78 WH RD c C c parage WH A A un KS1 48 30 86 gt KEY SWITCH Cni B POWER 4 E RELAY Tes 5 p o L ee i TO U5 OR E I B UM UU ga o J J i
76. 1930 Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Platform in the stowed position Key switch in the off position with the key removed Wheels chocked All external AC power supply disconnected from the machine Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death FJ Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbo
77. 2500 psi 172 bar 4 gpm 15 L min 10 micron with 25 psi 1 7 bar bypass Hydraulic tank return filter Function manifold System relief valve pressure 3500 psi 241 bar Lift relief valve pressure 3000 psi added after serial number 35799 207 bar Steer relief valve pressure 1500 psi 103 bar Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 2 Specifications Eee a eee LLL REVC Manifold Component Specifications Plug torque SAE No 2 50 in Ibs 6 Nm SAE No 4 13 ft Ibs 18 Nm SAE No 6 18 ft Ibs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Valve Coil Resistance Description Specification Solenoid valve 3 position 4 way 25 to 27 Q 20V DC with diode schematic item AF and BI Solenoid valve 2 position 4 way 18 to 20 Q 20V DC with diode schematic item AG Solenoid valve N O poppet 25 to 27 Q 20V DC with diode schematic item AH Solenoid valve 3 position 4 way 18 to 20 Q 20V DC with diode schematic item Al and BJ Solenoid valve 2 position 4 way 18 to 20 O 20V DC with diode schematic item BG Part No 72876 Genie GS 1530 and GS 1930 2 5 Section 2 Specifications April 2003 a SSNS SS SS SPECIFICATIONS REVC Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with either 37 flared fittings and hose ends OR Parker Seal Loke fittings and hose e
78. 3 FUNCTION MANIFOLD 6 2 Function Manifold Components after serial number 35799 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Diagnostic nipple BA Testing 2 Flow regulator 0 75 gpm 2 8 L min BB eon Steer circuit 3 Relief valve 3500 psi 241 3 bar System relief 4 Relief valve 3000 psi 207 bar Lift 5 Orifice washer 0 040 in 1 mm Steer circuit 6 Relief valve 1500 psi 103 4 BE knees Steering relief 7 Solenoid valve 2 position 4 way BG Platform up 8 Check valve 10 psi 0 7 bar Drive 9 Solenoid valve 3 position 4 way gt ees Steer left right 10 Solenoid valve 3 position 4 way Drive forward reverse 11 CHECK eiiis eines BK ines Steer circuit REV B Torque 35 ft lbs 47 Nm 20 ft lbs 27 Nm 20 ft Ibs 27 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 25 ft lbs 34 Nm 20 ft lbs 27 Nm 4 58 Genie GS 1530 and GS 1930 Part No 72876
79. 4 Repair Procedures April 2003 GROUND CONTROLS 4 4 Tilt Level Sensor before serial number 50444 How to Install and Calibrate the 1 5 Level Sensor This procedure is for models equipped with a 1 5 side 3 front 5 rear level sensor Type Serial range GS 1530 Australia from 24998 to 50443 GS 1930 ANSI CSA from 24998 to 50443 GS 1930 Australia from 48338 to 50443 GS 1932 Australia outdoor before 50444 ADANGER Tip over hazard Failure to install or calibrate the tilt level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls REV B 3 Block the wheels at the non steer end of the machine 4 Center a lifting jack under the drive chassis at the steer end of the machine 5 Raise the machine approximately 2 inches 5 cm 6 Place a 0 91 x 6 x 6 inch 23 1 mm x 15 cm x 15 cm thick steel block under both wheels at the steer end of the machine 7 Lower the machine onto the blocks 8 Raise the platform 7 to 8 feet 2 1 to 2 4 m
80. 5 4 HIGH TORQUE LED L21 BATTERY LEVEL 1 4 BATTERY LEVEL 2 BATTERY LEVELS gt 37 BATTERY LEVEL 4 4 BATTERY LEVELS 4 PLATFORM CONTROLS MEMBRANE DECAL PANEL 4 HIGH TORQUE BN6 HORN BN5 5 LIFT ENABLE BN9 H1 aarm Iz PIN11 PLATFORM CONTROLLER Part No 72876 Genie GS 1530 and GS 1930 6 14 April 2003 Section 6 Schematics E Electrical Schematic from serial number 17408 to 21064 Section 6 Schematics April 2003 Electrical Schematic REVE from serial number 21065 to 21262 1 QD4 WH RD c a WH A A KS1 BL B B CN KEY SWITCH b ENT off re oo f T 39C OR E 1 2 P1 B e NL 000 0U0UQGoe RE 7 EMERGENCY NC 4 NO N CHO CIRCUIT STOP A 2 BREAKER PLATFORM H5 CT D MULTI FUNCTION J M LS6 PS2 LS7 i DOWN PLATFORM POTHOLE LIMIT SWITCH OVERLOAD GUARD o15 PRESSURE SWITCH leB SWITCH if oe OPTION Neo i
81. 76 April2003 Section 5 Troubleshooting Flow Charts REVA Limit Switch Function inoperative Be sure the circuit breaker and fuse are not tripped or blown Be sure the limit switches are clear of debris Be sure the pothole guards are deploying Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the position and the platform the stowed position check voltage on the WH B10 pothole sw wire at the ECM U5 ov Check voltage at down oV limit switch LS6 Is there 20V or more on one side of LS6 20V or more With the platform raised ov to 6 feet 1 8 m check for 20V or more on one side of LS8 20V or more Check for 20V or more OV on both sides of LS7 20V or more Repair or replace the wire circuit between LS7 and the positive terminal at alarm H5 20V or more Chart 15 Adjust the pothole limit switch LS7 OR adjust pothole limit switch LS8 Check voltage on the oV other terminal at LS6 Adjust LS6 OR replace the LS6 contacts 20V or more Repair or replace the 44D wire from alarm H5 to LS6 Check LS8 for correct good adjustment Repair or replace the wire circuit between terminal B10 at ECM U5 and LS8 OR replace U5 bad Adjust LS8 Check LS7 for correct good Replace the LS8 adjustment contacts OR repair or r
82. 8 U13 HOUR FLASHING AUTOMOTIVE STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM 1 DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP jj Hors uum OPTION OPTION OPTION OPTION i 8 EI _ L_ e e GND GND 6 21 Genie GS 1530 and GS 1930 Part No 72876 REV BK RD 3 V WH ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable BN9 Lift enable CB2 Circuit breaker 7A CR Control relay 5 Horn relay with H2 option CR48 Power relay to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons Gauge G6 Hour meter G7 Battery charge indicator GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole 5 Motor N C Normally closed N C H O Normally closed held open Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure swit
83. 9 A12 B12 Att c12 B9 A10 B10 C2 B11 A4 A2 Bi Ci C11 A5 OUT OUT OUT N N IN IN OUT IN IN IN IN IN IN IN IN IN OUT 1 Al U5 U9 A1 OUT ELECTRONIC CONTROL MODULE 6 4 BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT B3 C7 B7 7 C6 B6 A6 rj AC INPUT OT2 BO Sky i oe ep gee ES Fe AA i 9 9 x g g 2 D i 4 a 5 cK 1 8 4 o 2 g F8 p i 8 8 8 50A FUSE U6 motor Jt 7 CONTROLLER a FB l STN 1013 G6 FB H2 Y3 Y4 Y5 Y6 Y8 l HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM INVERTER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION p E X X X X A X X Li Le GND GND 8 5 gt 6 33 Genie GS 1530 and GS 1930 Part No 72876 April 2003 SSS SS See Electrical Schematic REV B M L K J H 4 4 BK POWER TO PLATFORM CONTROLS t 3 3 RD POWER TO GROUND CONTROLS a 1 1 WH GROUND WH NS 2 2 BL DATA LINK HIGH 5 5 OR DATA LINK LOW ABBREVIATION LEGEND QD3 Item Description bo 4 B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay CR5 Horn relay with H2 option CR48 Power relay
84. 930 3 9 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 3 Inspect the Tires and Wheels including castle nut torque Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion 1 Checkthe tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks 3 Remove the cotter pin and check each castle nut for proper torque Refer to Section 2 Specifications Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Install a new cotter pin Bend the cotter pin to lock it in place REVC B 4 Test the Key Switch Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the k
85. ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay CR5 Horn relay with H2 option CR48 Power relay to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect Control cable to ground QD4 Control cable to platform R21 75 ohm resistor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch U Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Y Valve coil Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platfo
86. AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspectthe following areas for burnt chafed corroded and loose wires Ground control panel Hydraulic power unit module tray Battery pack module tray Scissor arms Platform controls 2 Inspectfor a liberal coating of dielectric grease in all connections between the ECM and the platform controls 3 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 CHECKLIST B PROCEDURES Raise the platform approximately 8 feet 2 4 m from the ground Rotate the safety arm away from the machine and let it hang down Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Inspect the center chassis area and scissor arms for burnt chafed and pinched cables Inspect the following areas for burnt chafed corroded pinched and loose wires ECM to platform controls Powerto platform wiring Inspect for a liberal coating of dielectric grease in all connections between the ECM and the platform controls 10 Raise the platform and return the safety arm to the stowed position 11 Lower the platform to the stowed position and turn the machine off Part No 72876 Genie GS 1530 and GS 1
87. B PROCEDURES Models after serial number 35799 1 Lubricate each module tray rotary latch Using light oil apply a few drops to each of the springs and to the sides of the rotary latch mechanism a rotary latch springs b module tray rotary latch Inspect each module tray latch U bolt Tighten any loose U bolt retaining fastener before the latch fails to securely hold the module tray closed Part No 72876 Genie GS 1530 and GS 1930 3 17 Section Scheduled Maintenance Procedures April 2003 Checklist C Procedure C 1 Check the Scissor Arm Wear Pads Maintaining the scissor arm wear pads in good condition is essential to safe machine operation Continued use of worn our wear pads may result in component damage and unsafe operating conditions Perform this procedure with the platform in the stowed position 1 Measure the thickness of each scissor arm wear pad at the non steer end of the machine 2 Replace both wear pads if either one is less than 0 21 inch 5 3 mm thick Refer to Repair Procedure 3 1 or 3 2 How to Replace the Scissor Arm Wear Pads 3 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact Scissor arm wear pad specification Wear pad thickness minimum 0 21 inch 5 3 mm E w la EX 0 21 5 3 REVC 3 18 Genie GS 1530 an
88. BN 1 F6 e 275A FUSE pce zd B8 A9 A12 B12 11 C12 B9 A10 B10 C2 B11 A4 A2 Bi Ci Cii AS OUT OUT OUT N N IN IN OUT IN IN IN IN IN IN IN IN IN OUT kie l US 6 U9 1 OUT ELECTRONIC CONTROL MODULE CHARGER OUT OUT OUT OUT OUT OUT OUT B3 C7 B7 A7 B6 A6 AC INPUT wa yo ee ee S i 1 9 9 g x g g amp o 2 ad 2 c a UU g 3 E z Q Q 7 U6 sdz i 8 8 8 8 50A FUSE MOTOR NC rm i CONTROLLER FB U13 G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8 l HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM DC AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION _ 4 X T X A X 4 X A X 4 X 8 e Li _ Li e e GND GND La P 5 6 31 Genie GS 1530 and GS 1930 Part No 72876 April 2003 REV B M L K J H Za POWER TO PLATFORM CONTROLS A A RD POWER TO GROUND CONTROLS p B B WH GROUND R V D D BL DATA LINK E E YL DATA LINK ABBREVIATION LEGEND QD3 Item D
89. D1 continuity Check voltage on ov terminal D1 at the pump motor M6 20V or more Continued on the next page REVA Troubleshoot ground and platform control systems separately OR consult the Genie Industries Service Department Repair or replace the wire circuit from the platform controls to CR48 OR repair or replace the CR48 socket OR replace CR48 Replace F6 OR check for short circuits OR check battery cables OR check for open in negative battery cable from batteries to ground point on module tray Repair open in the negative battery cable from the B terminal at motor controller U6 to QD1 Repair open in the 24V cable circuit from F6 to QD1 OR replace or repair QD1 OR repair open in 24V cable circuit from QD1 through terminal B at U6 to terminal D1 at M6 Genie GS 1530 and GS 1930 Part No 72876 April2003 REVA Continued from the previous page Check voltage at input side of Emergency Stop button P1 20V or more Check voltage at the input side of each contact at key switch KS1 20V or more Check the output side of the platform control contact at KS1 20V or more Turn KS1 to the ground control position and check output side of each contact 20V or more Refer to Chart 2 Pump Motor Will Not Operate OR repair open in WH wire C2 estop chassis OR consult the Genie Industries Service Department oV oV ov
90. EV B How to Determine the DIP Switch Configuration 1 Remove the platform controls from the platform 2 Place the platform controls close to the diagnostic display on the power unit side of the machine 3 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 4 Press and hold the lift function enable button OR press the lift function select button 5 Slowly move the joystick in the direction indicated by the blue arrow Result The DIP switch configuration will appear in the diagnostic display 4 12 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B How to Set the DIP Switch Codes ADANGER Tip over hazard Do not adjust the DIP switch settings to other than what is specified in this procedure Exceeding specifications could cause the machine to tip over resulting in death or serious injury If replacing the circuit board note the toggle positions on the DIP switch Set the DIP switch on the new circuit board to the same configuration as the old board 1 Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Remove the fasteners securing the top of the platform controls and open the platform control box 3 Rotate the platform control box to the position shown to correctly identi
91. GROUND V CONTROL 3 TS66 LS8 PLATFORM iuis UP DOWN SWITCH SICH 2 z 5 r 7 a 30 86 5 4 Fa HORN RELAY 8 8 s 8 8 2 2 E x 20255 2 i XN d o Q h i m m 33 87 85 H2 OPTION 5 c c c ze 2 5 BS E 9 J RE 9 a2 EE P oo LEVEL 9 E g 2 gt P a3 LEE 9 g SENSOR I 1 223 253 E E f gorii 8 R21 8 8 o o d 4 258059 2 5 BOARD 2 93 2 Q 664 r3 m 75 OHM gt 5 E 287 68 t S a U27 3 m 5 A a8 S7 47 mH amp 3 LEVEL p A QD1 9 A es m g SENSOR 5 SUPPRESSION E 1 r BN F6 275A FUSE D1 l _ ee m B8 8 A9 12 12 C2 B9 Bi C12 A10 Bi0 1 B2 A4 A2 Ci Cii A5 OUT OUT OUT IN IN OUT IN IN IN IN IN OUT IN IN IN IN IN OUT 1 Ai OUT US 6 ELECTRONIC CONTROL MODULE a U9 BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT OUT B3 Co C7 B7 AT C6 B6 A6 AC INPUT OR BO Vd mnc dd d MG A AT 2 g g E g 8 5 E 3 m m i 5 po _ 3 8 4 5 2 8 7 F8 sd li 8 8 8 8 FUSE U6 motor 3 E m CONTROLLER FB LTS U13 H2 Y2 YA Y5 Y6 Y7 Y8 l HOUR FLASHING AUTOMOTIVE STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM INVERTE
92. GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 5 Loosen the adjustment nuts on the solenoid then disconnect the manual lowering cable from the solenoid During assembly the manual platform lowering cable needs to be properly adjusted See 4 1 How to Adjust the Manual Platform Lowering Cable 6 Remove the mounting fasteners from the manual lowering cable mounting bracket Remove the bracket from the cylinder 7 Before serial number 23568 Disconnect and plug the hydraulic hardline from the lift cylinder Cap the fitting on the cylinder After serial number 23567 Disconnect and plug the hydraulic hose from the lift cylinder Cap the fitting on the cylinder AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 8 Before serial number 23568 Remove the hardline retaining strap from the cylinder 9 Attach a lifting strap from an overhead crane to the rod end of the lift cylinder for support 10 Remove the external snap ring from the lift cylinder rod end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while lowering the cylinder SCISS
93. Hydraulic Pump When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the mounting fasteners from the hydraulic filter bracket at the function manifold Push the filter off to the side 2 Tag disconnect and cap the hydraulic hoses on the pump AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Remove the pump mounting bolts Carefully remove the pump Tip over hazard After replacing A DANGER the hydraulic pump it is critical to return the lift speed and raised drive speed settings to original factory specifications Failure to restore the machine to original factory specifications could cause the machine to tip over resulting in death or serious injury Part No 72876 Genie GS 1530 and GS 1930 4 55 Section 4 Repair Procedures April 2003 Function Manifold 6 1 REV B Function Manifold Components from serial number 17408 to 35799 The function manifold is mounted inside the hydraulic power unit module tray Index Schematic No Description Item Function Diagnostic nipple BAO Testing 2 Flow regulator
94. INIO 6 POUT11 11 PLATFORM CONTROLLER WIRE COLOR LEGEND Color Description BL Blue 8 BK Black BN Brown GN Green OR Orange RD Red WH White YL Yellow Part No 72876 Genie GS 1530 and GS 1930 6 16 April 2003 Section 6 Schematics es Electrical Schematic from serial number 21065 to 21262 Section 6 Schematics April 2003 E Electrical Schematic REVC from serial number 21263 to 25141 WH RD c c WH A A a KSI BL B B E KEY SWITCH x gt 7 a TT BK D D n pe _ T r t 396 OR E C E CB2 P1 Be pg SI 1 7A EMERGENCY 8 NC 4 NO N CHO 2 CIRCUIT STOP 5 BREAKER i V MULTI FUNCTION l ALARM LS6 PS2 LS7 EE DOWN PLATFORM POTHOLE LIMIT SWITCH OVERLOAD GUARD o18 PRESSURE SWITCH dB SWITCH oe OPTION Neno 4 ES GROUND 1 V CONTROL 3 EL ee TS66 LS8 PLATFORM PETOLE UP DOWN SWITCH
95. Inspection Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the Genie GS 1530 and GS 1930 Operator s Manual Refertothe Operator s Manual on your machine REVC A 2 Perform Function Tests Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the Genie 65 1530 and GS 1930 Operator s Manual Refer to the Operator s Manual on your machine 3 6 Genie GS 1530 and GS 1930 Part No 72876 June 2006 Section 3 Scheduled Maintenance Procedures REV A 3 Perform 30 Day Service The 30 day maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50 hours of use After this interval refer to the maintenance checklists for continued scheduled mainten
96. ON ii eee JC1 U3 b JOYSTICK PLATFORM CONTROLLER CONTROLS CIRCUIT 9 tL 34 BOARD C c O o gu Models before serial number 51015 potentiometer equipped joystick P2 EMERGENCY STOP BUTTON e E e y PLATFORM CONTROLS CIRCUIT BOARD HE E errrie L ei n n ALARM KW Models after serial number 51014 hall effect joystick a red Emergency Stop button P2 b platform controls circuit board U3 C circuit board retaining fastener d circuit board voltage regulator D7 e alarm H1 f joystick controller JC1 g potentiometer R15 h DIP switch SW25 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid 3 Locate the membrane circuit board mounted to the inside of the platform control box lid AWARNING Electrocution hazard Contact with electrically charged c
97. OR COMPONENTS 11 Lower the cylinder 12 Support and secure the entry ladder to an appropriate lifting device 13 Remove the fasteners from the entry ladder and remove the entry ladder from the machine AWARNING Crushing hazard The entry ladder could become unbalanced and fall if not properly supported and secured to the lifting device 14 Attach a lifting strap from an overhead crane or similar lifting device to the barrel end of the lift cylinder for support 15 Remove the external snap ring from the lift cylinder barrel end pivot pin Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported when the pin is removed 16 Support and secure the lift cylinder to an appropriate lifting device 17 Remove the lift cylinder through the scissor arms at the non steer end of the machine Component damage hazard Be CAUTION careful not to damage the valve or fittings on the cylinder while removing it from the machine Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 Ground Controls 4 1 Manual Platform Lowering Cable The manual platform lowering cable lowers the platform in the event of a main power failure The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls How to Adjust the Manual Platform Lowering Cable 1 Raise the platf
98. OR consult the Genie Industries Service Department bad Replace SW6 Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April 2003 CHART 9 previous page Continued from the REVA Remove the mechanical restrictions Install a 0 to 2000 psi Are there mechanical 138 bar pressure restrictions keeping the gauge at the quick steer left function from disconnect coupling on moving the function manifold and activate the steer right function Repair or replace the steer cylinder OR consult the Genie less than Industries Service 1500 PSI Department Reset the steer relief Repair or replace the valve pressure steer cylinder OR item AE or BF replace the steer left See Repair Section right valve cartridge item AF or OR the less than function manifold could 1500 PSI have an internal defect Consult the Genie Replace the steer relief Industries Service valve item AE or BF Department 5 16 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA All Drive Functions Inoperative All Other Functions Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are f
99. OUT U5 6 U9 ELECTRONIC CONTROL MODULE BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT 5 B3 C7 B7 A7 C6 B6 AG p AC INPUT Of BO Vly Jq ee ee ee On 30 FB FTN e E E E m m E z T Hla J Q 4 S S 2 7 F8 ne Q Q 8 Q Q 9 23 sdy E g 2 8 2 50A FUSE U6 MOTOR a h d CONTROLLER FB L I B DA eee eee as 1013 G6 FB H2 Y3 Y4 Y5 Y6 Y7 Y8 HOUR FLASHING AUTOMOTIVE STYLE STEER STEER DRIVE DRIVE PLATFORM PLATFORM i DC AC INVERTER METER BEACONS HORN RIGHT LEFT REVERSE FORWARD DOWN ql OPTION OPTION OPTION OPTION 8 E L_ L_ GND GND 6 25 Genie GS 1530 and GS 1930 Part No 72876 REV B BK RD H POWER TO PLATFORM CONTROLS April 2003 Section 6 Schematics T Electrical Schematic from serial number 40926 to 49804 POWER TO GROUND CONTROLS WH ABBREVIATION LEGEND Item Description B5 Battery BN Button BN5 Horn BN8 Drive enable BN9 Lift enable CB2 Circuit breaker 7A CR Control relay CR5 Horn relay with H2 option CR48 Power relay to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons Gauge G6 Hour meter G7 Battery charge
100. OWN ALARM PLATFORM POTHOLE V Gontron 1 LIMIT OVERLOAD GUARD 218 Maes es SWITCH PRESSURE SWITCH TS66 SWITCH 3 PLATFORM OPTION NCHO 4 UP DOWN SWITCH 8 5 LS8 v 3 POTHOLE GUARD SWITCH F 30 86 i CR5 4 i UNE a T 8 g 3 Q 8 2 8 zg 255 2 gi 4 il gt zi m 5 55 E T 87 85 H2 OPTION 5 5 3 D 29 qi oe m ox 88 z 9 1 53 zz lt d I o o 2 o 3 35 23 o d A amp 6i pope R21 3l 8 8 2 amp Us 5 2 fi BOARD o z z d 5 lt 75 OHM 21 3 3 2 2 2 gt 2 E eomm iB t 4 m 8 5 2 5 2 U27 E 2 o o a 7 47 mH a d 3 a LEVEL INDUCTOR m SENSOR QD1 9 NOISE 9 hoger SUPPRESSION ts Bh F6 e 275A FUSE LLL LL B8 A9 A12 B12 AM C12 B9 A10 B10 C2 A4 B11 A2 Bi Ci Cii A5 OUT OUT OUT N IN IN IN OUT IN IN IN IN IN IN IN IN IN OUT A1 OUT U5 6 U9 ELECTRONIC CONTROL MODULE BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT OUT B5 B3 C9 C7 B7 7 C6 B6 A6 LL I III I eee _ M 3 _ e __ __ M _ ac INPUT Vly 4 6V BATERY FB gt m gt perche PME STS 2 8 9 9 o e E 2 c _ 2 d m m E z F 3 3 3 5 3 8 7 Ty F8 Sean 8 8 9 8 8 F zi 50A FUSE U6 motor 3 1 E 9 9 CONTROLLER e FB L rn G6 2 FB H2 Y2 Y3 Y4 Y5 Y6 Y7 Y
101. Platform stowed 2 5 mph 40 ft 10 7 sec Quantity 8 4 km h 12 2 m 10 7 sec Battery capacity maximum 225AH Platform raised 0 5 mph Reserve capacity 25A rate 447 minutes 40 ft 55 sec 0 7 Fluid capacities 12 2 m 55 sec Hydraulic tans i gallons Braking distance maximum 18 9 liters Hydraulic system including tank 5 5 gallons High range on paved surface 61 20 8 liters Tiros and wheels Load capacity maximum Tire size solid rubber 12x4 5x8 6 in LEX ALR EN Platform only 350 Ibs Tire contact area 9 sq in 159 kg 58 sq cm Extension only 250 Ibs 113 kg Overall tire diameter 12 in 30 5 cm Function speed maximum from platform controls with 1 person in platform Wheel diameter 8 6 in 21 8 cm Platform up 15 to 17 seconds Platform down 16 to 18 seconds Wheel width 4 5 in 11 4cm _ Airborne noise emissions lt 70 dB Maximum sound level at normal operation workstations Castle nut torque dry 300 ft lbs A weighted 406 7 Nm a ST Gradeability 30 Castle nut torque lubricated 225 ft lbs 305 Nm Continuous improvement of our products is a Genie policy Product specifications are For operational specifications refer to the subject to change without notice Operators Manual Part No 72876 Genie GS 1530 and GS 1930 2 1 Section 2 Specifications April 2003 SPECIFICATIONS Machine Specifications GS 1930 Batteries Type 6V DC
102. R METER BEACONS RELEASE RIGHT LEFT REVERSE FORWARD DOWN UP OPTION OPTION OPTION OPTION 1 X AUOX a X 4 X A X X a X 8 Ls r e L_ L_ GND 6 15 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics T Electrical Schematic from serial number 21065 to 21262 REV C M L K ABBREVIATION LEGEND Item Description 5 Battery BN Button BN5 Horn Lift enable CB2 Circuit breaker 7A CR5 Horn relay with H2 option D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick dis
103. Remove the number 2 outer arm index 21 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 2 outer arm index 21 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine 41 Attach a lifting strap from an overhead crane to the number 2 inner arm index 20 42 Remove the external snap rings from the number 2 pivot pin index 9 at the steer end of the machine 43 Use a soft metal drift to remove the number 2 pivot pin index 9 Remove the number 2 inner arm index 20 from the machine ACAUTION Bodily injury hazard The number 2 inner arm index 20 may become unbalanced and fall if not properly supported when it is removed from the machine 44 Remove the safety arm from the number 2 inner arm index 20 that was just removed 45 Attach a lifting strap from an overhead crane to the number 1 inner arm index 11 REVA 46 Raise the number 1 inner arm index 11 approximately 2 feet 60 cm and install the safety arm between the number 1 inner arm index 11 and the number 1 outer arm index 24 Lower the scissor arms onto the safety arm ACAUTION Bodily injury hazard Keep hands clear of moving parts when lowering the scissor arms onto the safety arm 47 Tag disconnect and plug the hydraulic hose on the lift cylinder Cap the fitting on the cylinder AWARNING cine injury hazard Spraying ydraulic
104. Repair or replace P2 OR replace control cable from U5 to the platform controls 20V or more Check voltage on oV terminal A4 at U5 Replace control cable from U5 to the platform controls 20V or more Replace control cable from U5 to the platform controls OR replace the platform controls OR consult the Genie Industries Service Department 5 10 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA Platform Up Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Models with lift function enable button With the key switch turned to platform controls and both m Emergency Stop buttons light is pulled out to the ON on position press and hold the lift function enable button and activate the controller in the UP direction and check to see if the error indicator light at the platform controls is on Models with drive function select button With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON D press the lift unction select button and activate the controller in the UP direction and check to see if the error indicator light at the platform controls is on light is not on install 010 5000 PSI 3000 350 bar
105. S7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform R Resistor R15 5000 ohm potentiometer R21 75 ohm resistor 57 Tilt level sensor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switch TS66 Platform up down toggle switch U Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller WIRE COLOR U9 Battery charger LEGEND U13 Voltage inverter option er U27 47 id inductor ie ere Color Description Y Valve coil BL Blue Y2 Brake release BK Black Y3 Steer right BN Brown Y4 Steer left GN Green Y5 Drive reverse OR Orange Y6 Drive forward RD Red Y7 Platform down WH White Y8 Platform up YL Yellow DIP SWITCHES 24V DC D7 VOLTAGE REGULATOR POUT1 t t POUT2 POUT3 POUT4 POUTS POUT6 POUT7 Ooo 0 0 9 POUT8 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD POUT11 JC1 Joystick CONTROLLER WH YL 5000 OHM SW6steer POTENTIOMETER S Eu SW5 FUNCTION ENABLE POWER LED L19 FAULT LED L2
106. Specifications GS 1530 cccccsecceeeeeesseeeeeeeeeseneeeeeeesessnseeeeeeeseeaaes 2 1 Machine Specifications GS 1930 0 ecccccccccceecesseeeeeeeesenaeeeeeeesseneeeeeeeessenaeeeeeeesssaaes 2 2 Performance Specifications GS 1930 ec ccccsccceeeeeesseeeeeeeeeeneeeeeeeeessneeeeeeeeseeaaes 2 2 Machine Specifications GS 1932 Australia Outdoor 2 3 Performance Specifications GS 1932 Australia Outdoor 2 3 Hydraulic Specifications All Models 2 4 Manifold Component Specifications ssrin aaau 2 5 Hydraulic Hose and Fitting Torque 2 6 Scheduled Maintenance Procedures INTRODUCTION 3 1 Pre delivery Preparation Report 3 3 Maintenance Inspection Report ssssssssseeenm eene mene 3 5 Checklist A Procedures Rev C A 1 Perform Pre operation Inspection sessssen 3 6 A2 Pertorm Function agus ees e ER RR CE RUE EAE LIP Eu 3 6 A 3 Perform 30 Day Service ssssssssssssseseeeeeeeeen nennen 3 7 4 Grease the Steer Yokes ssssssssssssssseeeeeeneeenee nennen nennen 3 7 Part No 72876 Genie GS 1530 and GS 1930 v September 2006 SSS TABLE OF CONTENTS Sec
107. achine 52 Lower the machine onto the blocks GROUND CONTROLS 53 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound O Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result If the platform does not stop or the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 54 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 55 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 56 Install the tilt level sensor box cover 57 Raise the platform 7 to 8 feet 2 1 to 2 4 m 58 Return the safety arm to the stowed position 59 Lower the platform to the stowed position 60 Raise the machine approximately 2 inches 5 cm 61 Remove the blocks from under both wheels 62 Lower the machine and remove the jack
108. alia after 50443 GS 1932 Australia outdoor after 50443 ADANGER Tip over hazard Failure to install or calibrate the tilt level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Remove the platform controls from the platform 2 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls Raise the platform 7 to 8 feet 2 1 to 2 4 m Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 5 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to step 15 7 Turn the key switch to the off position and push in the red Emergency Stop button to the off position at the ground controls 8 Tagand disconnect the wiring harness from the level sensor limit switch and alarm 9 Remove the tilt level sensor box retaining fasten
109. ance 1 Perform the following maintenance procedures B 3 Inspect the Tires and Wheels including castle nut torque B 11 Replace the Hydraulic Tank Return Filter CHECKLIST A PROCEDURES A 4 Grease the Steer Yokes Genie specifications require that this procedure be performed every 100 hours of operation Regular application of lubrication to the steer yokes is essential to good machine performance and service life Continued use of an insufficiently greased steer yoke will result in component damage 1 Locate the grease fitting on the top of the steer yoke 2 Pump multipurpose grease into the steer yoke until the steer yoke is full and grease is being forced past the bearings Repeat this step for the other steer yoke Grease type Multipurpose grease Part No 72876 Genie GS 1530 and GS 1930 3 7 Section Scheduled Maintenance Procedures September 2006 Checklist B Procedures B 1 Inspect the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills wi
110. ane to the number 2 outer arm index 21 at the ground controls side 34 Remove the external snap rings from the number 2 center pivot pin index 7 at the ground controls side 35 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the ground controls side SCISSOR COMPONENTS 36 Use a soft metal drift to tap the number 2 pivot pin index 22 halfway out at the non steer end of the machine Remove the number 2 outer arm index 21 from the ground controls side of the machine Bodily injury hazard The number ACAUTION 2 outer arm index 21 at the ground controls side may become unbalanced and fall if not properly supported when it is removed from the machine 37 Attach a lifting strap from an overhead crane to the number 2 outer arm index 21 at the battery pack side 38 Remove the external snap rings from the number 2 center pivot pin index 7 at the battery pack side 39 Use a soft metal drift to remove the number 2 center pivot pin index 7 at the battery pack side Bodily injury hazard The number ACAUTION 2 outer arm index 21 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS 40 Use a soft metal drift to tap the number 2 pivot pin index 22 in the other direction at the non steer end
111. atform controls Result The diagnostic display will show PS IN N Genie a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline button e lift function enable button BN9 f red Emergency Stop button P2 Release the lift function enable and horn buttons Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the maximum raised drive speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position Part No 72876 Genie GS 1530 and GS 1930 4 9 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS Software revision CO i Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position N Pull out the red Emergency Stop button to the on position at the ground and platform controls o Press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS Genie t function enable switch SW5 joystick controller JC1 with thumb steering roc
112. ative Ground Controls Operate Normally Rev A ssssseeeeeennnn 5 10 6 Platform Up Function Inoperative Rev 5 11 7 Platform Down Function Inoperative Rev A 5 12 8 Steer Left Function Inoperative Rev A 5 13 9 Steer Right Function Inoperative Rev A enne 5 15 10 All Drive Functions Inoperative All Other Functions Operate Normally Rev A 5 17 10A Brake Release Function Inoperative Rev A 5 18 11 Drive Forward Function Inoperative Rev A ssssss 5 19 12 Drive Reverse Function Inoperative Rev A 5 20 13 Machine Will Not Drive At Full Speed Rev A 5 21 14 Machine Drives At Full Speed With Platform Raised Rev A 5 22 15 Limit Switch Function Inoperative Rev A 2 222 5 23 16 Fault Code 02 Platform Communication Error Rev 5 24 viii Genie GS 1530 and GS 1930 Part No 72876 April 2003 TABLE OF CONTENTS Section Six Schematics INTOGUCTION PE EE 6 1 Electrical Components REV C erdt rne
113. ay service Hour meter Perform every 100 hours B 4 Emergency stop B 5 Key switch Machine owner A 4 Grease steer yokes B 6 Horn if equipped Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hour Inspection A Quarterly or 250 hour Inspection A B Annual or 1000 hours Inspection A B C 2 Year or 2000 hour Inspection A B C D Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Comments B 7 Drive brakes B 8 Drive speed stowed B 9 Drive speed raised B 10 Hydraulic oil analysis B 11 Hydraulic tank return filter B 12 Latch components Checklist C Rev C Y NR C 1 Scissor arm wear pads Checklist D Rev Y NR D 1 Hydraulic oil Part No 72876 Genie GS 1530 and GS 1930 Section Scheduled Maintenance Procedures April 2003 Checklist A Procedures A 1 Perform Pre operation
114. box module tray rotary latch battery quick disconnect QD1 275A fuse F6 automotive style horn H2 option multi function alarm H5 CR5 horn relay tilt level sensor S7 Rr ED 6 6 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics a This page intentionally left blank Part No 72876 Genie GS 1530 and GS 1930 6 7 Section 6 Schematics April 2003 Platform Controls Wiring Diagram from serial number 17408 to 51014 SW25 DIP SWITCH P2 EMERGENCY STOP BUTTON JC1 JOYSTICK CONTROLLER OR PP WH WH RD WH BL e D RD U3 PLATFORM CONTROLS CIRCUIT BOARD In YE OR REV WIRE COLOR LEGEND COIL Color Description CORD BL Blue ASSEMBLY BK Black BN Brown GN Green ABBREVIATION LEGEND OR Orange Item Description Purple v BEI EB WH White JC1 Joystick controller WHIBL White Blue 2 Emergency Stop button at platform controls WH BK White Black SW25 DIP switch WH RD White Red US Platform controls circuit board YL Yellow 6 8 Genie GS 1530 and GS
115. ch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R15 5000 ohm potentiometer R21 75 ohm resistor Sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression BL YL WIRE COLOR LEGEND Color Description Valve coil BL Blue Y2 Brake release Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up BK Black BN Brown GN Green OR Orange RD Red WH White YL Yellow H POWER TO PLATFORM CONTROLS April 2003 Section 6 Schematics Electrical Schematic from serial number 28937 to 35799 POWER TO GROUND CONTROLS GROUND DATA LINK HIGH DATA LINK LOW SW25 DIP SWITCHES 24V DC VOLTA REGULATOR U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD D7 GE POUT2 FAULT LED L25 POUT9 DRIVE LED L17 POUT10 C PIN9 8 PIN1
116. chsup genieind com Serial Number Information Genie Industries offers the following Service Manuals for these models Title Part No Genie GS 1530 and GS 1930 Service Manual before serial number 17408 39528 Copyright 1997 by Genie Industries 72876 Rev April 2003 Second Edition Third Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries Printed on recycled paper Printed in U S A li Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Genie GS 1530 and GS 1930 Operator s Manual will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 72876 Genie GS 1530 and GS 1930 lii Section 1 Safety Rules April 2003 SAFETY RULES Personal Safety Any per
117. connect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform R Resistor R15 5000 ohm potentiometer R21 75 ohm resistor 57 Tilt level sensor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switch TS66 Platform up down toggle switch U Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression Y Valve coil Y2 Brake release Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up J H G F E D B A BK POWER TO PLATFORM CONTROLS F2 E EMERGENCY STOP ye A A RD POWER TO GROUND CONTROLS 1 SLT B 3 B WH GROUND NS p DATA LINE HIGH JC1 Joystick conTROLLER YL DATA LINK LOW WH YL QD3 L 1 5000 POTENTIOMETER RI DIP SWITCHES 2 SW5 FUNCTION ENABLE 24V DC D7 VOLTAGE REGULATOR POUT1 a POWER LED L19 3 POUT2 O qe FAULT LED L25 POUT3 ES HIGH TORQUE LED L21 POUT4 qe BATTERY LEVEL 1 POUTS E BATTERY LEVEL2 POUT6 ay 4 BATTERY LEVEL3 gt 37 POUT7 6 BATTERY LEVEL4 POUTS BATTERY LEVELS 4 U3 PLATFORM CONTROLS PLATFORM CONTROLS MEMBRANE DECAL PANEL PRINTED CIRCUIT BOARD HIGH TORQUE BN6 HORN BN5 5 LIFT ENABLE BN9 PIN9 c PINS P
118. controller to the side Remove the return filter mounting bracket fasteners from the manifold Push the filter and accumulator out of the way Tag disconnect and plug the hydraulic pump inlet hose at the side of the hydraulic tank Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine 4 68 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 8 1 Yoke and Drive Motor How to Remove the Yoke and Drive Motor Assembly When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Center a lifting jack under the drive chassis at the steer end of the machine 3 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 4 Loosen the wheel castle nut Do not remove it Raise the machine approximately 6 inches 15 cm Place blocks under the chassis for support Crushing hazard The chassis AWARNING could fall if not properly supported 6 Remove the wheel castle nut Remove the wheel Steer Axle Components 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic o
119. d GS 1930 Part No 72876 April2003 Section Scheduled Maintenance Procedures Checklist D Procedure REV B D 1 Test or Replace the Hydraulic Oil Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced atthe two year inspection test the oil quarterly Replace the oil when it fails the test Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine 2 Openthe power unit module tray 3 Remove the drain plug from the hydraulic tank and allow all of the oil to drain into a suitable container Refer to Section 2 Specifications for capacity information AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Tag disconnect and plug the hydraulic tank return hose at the top of the hydraulic tank Remove the motor controller mounting bracket retai
120. d across the terminals Resistor 10W Genie part number 27287 COIL C Sy a A AMMETER 100 9V RESISTOR BATTERY ES o Ei jev ope e a multimeter b 9VDC battery c 10W resistor d coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Setamultimeter to read DC voltage The multimeter when set to read DC voltage should be capable of reading up to 800 mA FUNCTION MANIFOLD Connect the negative lead to the other terminal on the coil If testing a single terminal coil connect the negative lead to the internal metallic ring at either end of the coil Momentarily connect the positive lead from the multimeter to the positive terminal on the 9V battery Note and record the current reading At the battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 2096 the coil and or its internal diode are faulty and the coil should be replaced Part No 72876 Genie GS 1530 and GS 1930 4 67 Section 4 Repair Procedures April 2003 Hydraulic Tank 7 1 Hydraulic Tank The primary functions of the hydraulic tank are to cool clean and deaerate the hydrau
121. d has been tightened beyond finger tight The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service kit 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks 2 8 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section Scheduled Maintenance Procedures Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three
122. d of the machine 28 Block the wheels at the steer end of the machine 29 Center a lifting jack under the drive chassis at the non steer end of the machine 30 Raise the machine approximately 5 inches 13 cm 31 Place a 4 73 x 6 x 6 inch 12 1 x 15 x 15 cm thick steel block under both wheels at the non steer end of the machine 32 Lower the machine onto the blocks REV B 33 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 1 m Result The tilt sensor alarm should sound O Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result If the platform does not stop or the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 34 Lower the platform to the stowed position 35 Raise the machine approximately 5 inches 13 cm 36 Remove the blocks from under both wheels 37 Lower the machine and remove the jack 38 Remove the blocks from the wheels at the steer end of the machine
123. death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Two persons will be required to safely perform some troubleshooting procedures Part No 72876 Genie GS 1530 and GS 1930 5 1 Section 5 Troubleshooting Flow Charts April2003 TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction discovered Identify symptoms Troubleshoot Y problem still exists Perform repair Return to service probl
124. der Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray CAUTION Component damage hazard Hoses can be damaged if they are kinked or pinched 3 Remove the pin retaining fasteners from the barrel end pivot pin Remove the pivot pin Note the quantity and location of the spacers when removing the barrel end pivot pin Part No 72876 Genie GS 1530 and GS 1930 4 71 Section 4 Repair Procedures _ STEER AXLE COMPONENTS 8 3 Steer Bellcrank How to Remove the Steer Bellcrank 1 Remove the steer cylinder See 8 2 How to Remove the Steer Cylinder From serial number 17408 to 43000 Remove the retaining fastener from the center pivot pin of the bellcrank After serial number 43000 Remove the retaining fastener from the center pivot pin of the bellcrank Remove the pin Note the quantity and the location of the spacers on the bellcrank Block the non steer wheels Center a lifting jack under the drive chassis at the steer end Remove the retaining fasteners from the steer links at each end of the bellcrank Note the quantity and location of the spacers between the bellcrank and the steer links Raise the machine approximately 14 inches 36 cm P
125. e from QD1 to 5 Continued from the previous page continuity Activate the lift function Repair open in the WH and check voltage on A8 motor contr enable terminal 1 at U6 wire from terminal 1 at U6 to pin A8 of the AMP connector at ECM U5 20V or more Activate the lift function Repair open in the WH and check voltage on A9 motor cont enable terminal 3 at U6 wire from pin A9 at U5 to terminal 3 at U6 OR replace U5 OR consult the Genie Industries Service Department Replace M5 OR consult the Genie Industries Service Department Part No 72876 Genie GS 1530 and GS 1930 5 7 Section 5 Troubleshooting Flow Charts April 2003 Chart 3 All Functions Inoperative Power Unit Starts and Runs Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Be sure the hydraulic tank is filled to the correct level Check for a positive connection between electric motor and pump by removing pump from motor M5 leaving all hoses connected Visually check the coupling connection Replace pump coupling OR replace the pump OR replace M5 Test the hydraulic pump See Repair section Replace the pump Consult the Genie Industries Service Depa
126. e function manifold and securely tighten Torque to 25 ft lbs 34 Nm 14 In order install the reverse valve coil with white black and brown wires spacer washer and the forward valve coil with white and brown wires onto the valve For the machine to function correctly the reverse valve coil must be closest to the manifold 15 Install the coil nut onto the valve and tighten Torque to 60 in Ibs 7 Nm CHECKLIST B PROCEDURES 16 Connect the battery pack to the machine 17 Replace the brakes and repeat this procedure beginning with step 1 Referto Repair Procedure 9 1 How to Hemove a Drive Brake 18 Contact the Genie Industries Service Parts Department and order kit part number 105457 19 Install the new valve received in the kit and mark the new valve with a white paint pen to identify new valve installation 20 Repeat this procedure beginning with step 1 If the machine fails to stop within the specified stopping distance after installing new brakes please contactthe Genie Industries Scissors Service Department 1 800 536 1800 Ext 8710 Part No 72876 Genie GS 1530 and GS 1930 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 7 Test the Drive Speed Stowed Position Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation
127. e safety arm move it to the center of the scissor arm and rotate down to a vertical position 7 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 8 Mark the mounting position of the level sensor box on the drive chassis 9 Remove the level sensor box cover 10 Mark the mounting position of the level sensor on the level sensor box Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 11 Remove the level sensor box mounting fasteners and slide the box towards the non steer end of the machine as far as it can go Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch level sensor or wiring while moving the level sensor box 12 Secure the ends of the scissor arms together at both ends of the machine with a strap or other suitable device 13 Remove the pin retaining fasteners from the number 1 inner arm pivot pins item 11 at the steer end of the machine Use a slide hammer to remove the pins 14 Attach a lifting strap from an overhead crane to the steer end of the scissor arms 15 Slide the forks from a forklift under the scissor arms at the non steer end of the machine 16 Raise the scissor arms up with the overhead crane until the number 1 inner arm will clear the level sensor box Component damage hazard Be CAUTION careful not to damage
128. e serial number 36367 297382 Telemecanique ZB2 BE102 1 after serial number 36366 66818 Telemecanique ZBE102 iunt tene 1 ux Contact N C before serial number 36367 44990 Telemecanique 2 2 21026 1 after serial number 36366 66818 Telemecanique ZBE 102 2 1 6 2 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics E REV ELECTRICAL COMPONENTS Item Description Genie Part Manufacturer Manufacturer Qty Number Part Number Battery connector 19436 Anderson 6325 G1 1 R21 3c Resistor 75 ohm 51590 RS 10 38 75 ohm 1 TS66 issie Toggle switch SPDT position momentary 13037 Microswitch Control Inc TNT 127 uere 1 iiti Motor controller 24V DC 275A before serial number 47731 66047 Curtis oo eee eee 1204 036 1 after serial number 47730 78385 General Electric
129. e the blocks from the wheels at the non steer end of the machine 28 Block the wheels at the steer end of the machine 29 Center a lifting jack under the drive chassis at the non steer end of the machine 30 Raise the machine approximately 5 inches 13 cm 31 Place a 4 73 x 6 x 6 inch 12 1 x 15 x 15 cm thick steel block under both wheels at the non steer end of the machine 32 Lower the machine onto the blocks REV B 33 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 1 m Result The tilt sensor alarm should sound O Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result If the platform does not stop or the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 34 Lower the platform to the stowed position 35 Raise the machine approximately 5 inches 13 cm 36 Remove the blocks from under both wheels 37 Lower the machine and remove the jack 38 Remove the blocks
130. ecifications Turn the key switch to the off position Any change in software settings will not take effect until the key switch is turned to the off position 4 6 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B Software revision CO and higher k N 5 Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position Pull out the red Emergency Stop button to the on position at the ground and platform controls At the platform controls press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 290000 lt a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 d machine on incline button e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 7 PLATFORM CONTROLS Press the lift function select button Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications Turn the key switch to the off position Any change in software settings will not take effect
131. em Solved LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers will blink during normal operation codes and remain on with fault codes The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected 5 2 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 5 Troubleshooting Flow Charts neva Fault Code Chart after serial number 17407 Fault Code Problem Possible Causes Solution Internal ECM error EPROM not programmed Replace ECM 01 02 See Chart 16 ECM Platform communication error Malfunctioning control cable OR malfunctioning platform controls Troubleshoot control cable OR troubleshoot platform controls 03 12 See Chart 4 Undefined platform DIP switch settings Chassis up down toggle closed at start up DIP switch settings incorrect Malfunctioning up down switch Correct DIP switch settings Troubleshoot up down switch 18 See Charts 10 13 or 14 Pothole guard failure Malfunctioning pothole switch OR obstruction in pothole guard linkage Troubleshoot pothole switch OR remove obstruction 19 See Chart 15 42 See Chart 5 or Chart 8 43 See Chart 5 or Chart 9 Limit switch failure
132. eplace the wire circuit bad between LS8 and LS7 OR replace the LS7 contacts Adjust LS7 Part No 72876 Genie GS 1530 and GS 1930 5 23 Section 5 Troubleshooting Flow Charts Chart 16 Fault Code 02 ECM Platform Communication Error Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons oV pulled out to the ON position check for voltage on the positive terminal 1 of the Emergency Stop button P2 at the platform controls 20V or more Open the platform control box With the m negative lead of an ohmmeter connected to the negative terminal of the battery B5 check for voltage at terminal 1 of the voltage regulator on the platform controls circuit board U3 20V or more Continued on page 28 Before serial number 25142 Check for voltage on terminal B2 at the ECM U5 After serial number 25141 Check for voltage on terminal 30 at relay CR48 20V or more Disconnect the control cable quick disconnect oV plug at the ECM and check for voltage at terminal C of the quick disconnect plug 20V or more Connect the control cable quick disconnect plug at the ECM Disconnect the control cable quick disconnect plug at the platform and check for voltage at terminal C of the quick disconnect
133. er of the Scissor arm and rotate down to a vertical position 5 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Remove the tilt level sensor box cover retaining fasteners Remove the cover The tilt level sensor box is located on top of the chassis at the steer end of the machine If you are not installing a new level sensor proceed to step 15 7 Turn the key switch to the orr position and push in the red Emergency Stop button to the orF position at the ground controls 8 Tagand disconnect the wiring harness from the level sensor limit switch and alarm 9 Remove the tilt level sensor box retaining fasteners Remove the tilt level sensor box from the machine 10 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level sensor box Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures 11 Place the new tilt level sensor in the tilt level Steer end sensor box with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level o sensor box Install the level sensor retaining 0 fasteners v2 ADANGER Tip over hazard The tilt level sensor must be installed with the X on the level sensor base 0 1 closest to the long side of the ti
134. ers Remove the tilt level sensor box from the machine 10 Remove the tilt level sensor retaining fasteners Remove the tilt level sensor from the level sensor box Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures 11 Place the new tilt level sensor in the tilt level sensor box with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Install the level sensor retaining fasteners ADANGER Tip over hazard The tilt level sensor must be installed with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to install the tilt level sensor as instructed could cause the machine to tip over resulting in death or serious injury Steer end Non steer end scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener 0 9 Part No 72876 Genie GS 1530 and GS 1930 4 47 Section 4 Repair Procedures April 2003 12 Install the level sensor box onto the machine Install the level sensor box retaining fasteners 13 Connect the wiring harness to the level sensor limit switch and alarm 14 Turn the key switch to the ground control and p
135. ery pack side of the machine 29 Raise the machine approximately 2 inches 5 cm 33 GS 1530 GS 1930 Place a 0 76 x 6x 6 inch 19 3 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 1932 Place a 0 82 x 6x 6 inch 20 8 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 31 Lower the machine onto the blocks Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures 32 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound O Result The tilt sensor alarm does not sound Adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8 feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result The platform does not stop or the tilt sensor alarm does not sound Adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 33 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 34 Lower the scissor arms
136. escription Lem 4 B5 Battery BN Button BN5 Horn BN8 Drive enable Lift enable CB2 Circuit breaker 7A CR Control relay CR5 Horn relay with H2 option CR48 Power relay to U5 D7 Voltage regulator Platform controls circuit board F6 Fuse 275A FB1 Flashing beacons G Gauge G6 Hour meter G7 Battery charge indicator GND Ground H Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch L LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open P Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect Control cable to ground QD4 Control cable to platform R21 75 ohm resistor SW Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch U Electronic component WIRE COLOR U3 Encoder printed circuit board LEGEN D U5 Electronic control module in U6 Motor controller Color Description BL Blue U9 Battery charger BK Black U13 Voltage inverter option U27 47 mH inductor noise suppression BN Brown Y Valve coil GN Green Y3 Steer right GY Gray Y4 Steer left OR O
137. extension out from How to Remove the the platform and place it on a structure capable 3 of supporting it Platform Extension How to Replace the Platform 1 Lower the platform to the stowed position Extension Wear Pads 2 Extend the platform approximately 3 feet 1 m 1 Remove the Platform Extension See 2 2 How 3 Remove the platform controls from the platform to Remove the Platform Extension and lay them off to the side of the machine 2 Drill out the rivets which hold the wear pads in 4 Support the platform extension with a forklift at place the steer end Do not apply any lifting pressure 3 Install the new wear pads using new rivets 5 Attach a strap from the platform extension railings to the carriage on the forklift to help When installing new rivets make the surface of the wear pad 6 Remove the two retaining fasteners from each platform extension roller bracket assembly Remove each assembly from the machine Do not remove the platform roller bolt a roller bracket assembly b assembly retaining fastener c platform roller bolt Part No 72876 Genie GS 1530 and GS 1930 4 17 Section 4 Repair Procedures April 2003 Scissor Components REVA n O LH Qe Z 985 1530 Steer End NL Non steer End
138. ey switch to platform control 3 Checkthe platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control 5 Checkthe machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures _ M M M2 REVC CHECKLIST B PROCEDURES B 5 Test the Automotive style Horn if equipped A functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound Part No 72876 Genie GS 1530 and GS 1930 3 11 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 6 Test the Drive Brakes Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitati
139. fall if not properly supported 6 Remove the wheel castle nut Remove the wheel REV B 7 Tag disconnect and plug the hydraulic hoses on the drive motor Cap the fittings on the drive motor AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 8 Remove the drive motor mounting fasteners Remove the motor Torque specifications Drive motor mounting fasteners dry 75 ft lbs 101 7 Nm Drive motor mounting fasteners lubricated 56 ft lbs 76 3 Nm Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures eee REV B STEER AXLE COMPONENTS 8 2 4 Remove the pin retaining fasteners from the Steer Cylinder rod end pivot pin Remove the pin Note the quantity and location of How to Remove the the spacers when removing the rod end pivot Steer Cylinder 5 Remove the steer cylinder from the machine When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Block the non steer wheels 2 Tag disconnect and plug the hydraulic hoses from the steer cylin
140. feet 2 1 to 2 4 m O Result The platform should stop and an alarm should sound O Result The platform does not stop or the tilt sensor alarm does not sound Adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted 33 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 34 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 35 Install the tilt level sensor box cover 36 Raise the platform 7 to 8 feet 2 1 to 2 4 m 37 Return the safety arm to the stowed position 38 Lower the platform to the stowed position 39 Raise the machine approximately 2 inches 5 cm 40 Remove the blocks from under both wheels 41 Lower the machine and remove the jack Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 Hydraulic Pump REVB 5 1 4 Activate the platform up function from the Function Pump ground controls Result If the pressure gauge reads The hydraulic pump is attached to the motor which 3200 psi 221 bar immediately stop The pump makes up the Hydraulic Power Unit is good Result If pressure fails to reach How to Test the Hydraulic Pump 3200 psi 221 bar the pump is bad and will When removing a hose assembly need to be serviced or replaced or fitting the O ring on
141. fer to the Operators Manual Genie policy Product specifications are subject to change without notice Part No 72876 Genie GS 1530 and GS 1930 Section 2 Specifications April 2003 SPECIFICATIONS Hydraulic Specifications Hydraulic Oil Specifications Before serial number 52640 Hydraulic oil type Shell Donax TG Dexron III After serial number 52639 Hydraulic oil type Chevron Rykon MV equivalent Approximate SAE grade 5W 20 Viscosity index rating 200 Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron lll oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and have a minimum viscosity index rating of 150 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Premium ECO 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Mineral based Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult the Genie Industries Service Department before use REV Function pump Type Gear Displacement per revolution 0 244 cu in 4cc Flow rate
142. fy the configuration of the DIP switch settings sw25 N 2 uiv emercency pu STOP BUTTON low JC1 U3 JOYSTICK CONTROLLER PLAFOBM CONTROLS 1 CIRCUIT BOARD O il Bg iei PLATFORM CONTROLS 4 Locate the DIP switch on the circuit board Move the DIP switch settings to correspond with the configuration of the machine options indicated in the DIP Switch Code Chart m a platform controls circuit board U3 b enlarged view of DIP switch SW25 c joystick controller JC1 d DIP switch SW25 Close the lid and install the fasteners Confirm the settings See 1 3 How to Determine the DIP Switch Configuration Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position Any change in DIP settings will not take effect until the key switch is turned to the off position Part No 72876 Genie GS 1530 and GS 1930 4 13 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS DIP Switch Code Chart A mark in the column indicates that the machine configuration includes this option Eo o w w c me Diagnostic DP El 818 lt 3 Display Switch 9 8 Code Code o 22 5 Sz l 10 95 2 J O 00 00000000 0000100
143. g hazard The chassis AWARNING could fall if not properly supported 8 Remove the wheel castle nut Remove the wheel 9 Tag disconnect and plug the hydraulic hose from the brake Cap the fitting on the brake AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Place a lifting jack under the brake for support 11 Remove the fasteners that attach the brake to the drive chassis Remove the brake Crushing hazard The brake will A CAUTION fall if not properly supported when the mounting fasteners are removed Torque specifications Brake mounting fasteners dry 75 ft lbs 102 Nm Brake mounting fasteners lubricated 56 ft lbs 76 Nm Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 Brake Release Hand Pump Components REV 10 1 Brake Release Hand Pump Components The brake release hand pump manifold is mounted behind the entry ladder next to the battery charger Index Schematic No Description Item Function Torque 1 Check valve pilot operated B ais Manual brake release circuit 25 30 ft lbs 34 41 Nm 2 Shuttle valve Brake release 8 10 ft lbs 11 14 Nm 3 Hand PUMP teret Manual brake release
144. gnostic 29 HOO DIP switch code 01010000 Options motion beacon lift drive cut out Diagnostic 30 DIP switch code 01110000 Options motion beacon motion alarm lift drive cut out Diagnostic DIP switch code 01100000 Options motion beacon motion alarm Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 Platform Components 2 1 Platform How to Remove the Platform Perform this procedure with the platform extension fully retracted and locked in position 1 Lower the platform to the stowed position 2 Disconnect the battery packs from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry 3 Remove the retaining fastener securing the platform controls quick disconnect plug to the bottom of the platform 4 Twist to disconnect the plug from the platform controls 5 Remove the cover from the AC outlet Label and disconnect the wiring from the outlet AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 6 Pull the wiring through the platform tube If your machine is equipped with an air line to platform option the air line must be disconnected from the platform before removal REVA 7 Support the platform with a f
145. hazard CAUTION Cables can be damaged if they are kinked or pinched Section 4 Repair Procedures SCISSOR COMPONENTS 3 Attach a lifting strap from an overhead crane to the number 3 outer arm index 13 4 Remove the external snap rings from the number 3 center pivot pin index 2 5 Use a soft metal drift to remove the number center pivot pin index 2 6 Remove the external snap rings from the number 3 pivot pin index 14 7 Usea soft metal drift to remove the number 3 pivot pin index 14 Remove the number 3 outer arm index 13 from the machine ACAUTION Bodily injury hazard The number 3 outer arm index 13 may become unbalanced and fall if not properly supported when it is removed from the machine 8 Remove the cable clamps from the number 3 inner arm index 12 9 Remove the mounting fasteners from the cable tray support at the steer end 10 Remove the external snap rings from the number 2 center pivot pin index 5 at the ground controls side Do not remove the pin 11 Slide the cable tray towards the battery pack side of the machine Remove it from the machine and lay it off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS 12 Attach a lifting strap from an overhead crane to the lug on the rod end of the
146. he Genie Industries Service Department Replace the platform up directional valve coil item AG or BG Remove the mechanical restrictions keeping platform up function from moving Part No 72876 Genie GS 1530 and GS 1930 5 11 Section 5 Troubleshooting Flow Charts April 2003 Chart 7 Platform Down Function Inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the on position and the platform raised slightly Models with lift erit enable utton press and hold liant i the lift function enable ight button and activate the controller in the DOWN direction and check to see if the error indicator light is on Models with drive function select button press the lift function select button and activate the controller in the DOWN direction and check to see if the error indicator light is on light is not on Replace the platform controls OR replace the ECM U5 OR consult the Genie Industries Service Department With the platform raised and the safety arm installed connect the leads of a volt meter to the wires on the platform lowering coil item D on the cylinder without removing the wires Models with lift function enable button
147. he inuity the yellow data line Department platform controls quick from pin E of the disconnect to terminal platform controls quick B1 at U5 disconnect to terminal C1 at U5 no continuity Replace the coil cord no continuity assembly OR replace the control cable from the platform to U5 Replace the coil cord assembly OR replace the control cable from the platform to U5 REVA 5 26 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 6 Schematics Observe and Obey M Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie GS 1530 and GS 1930 Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Schematics AboutThis Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING redd injury hazard Spraying ydraulic oil can
148. heels at the wheels steer end of the turn machine Jack the non steer end of the machine up approximately 4 inches 10 cm and place jack stands under the machine for support Turn the brake release knob item A counterclockwise all the way and pump the hand pump item C fully 13 15 times or until much resistance is felt Turn each wheel by hand Each wheel should turn freely without much effort Turn the brake release wheels valve item A clockwise turn all the way and try to rotate the wheels wheels do not turn Attempt to drive the machine in either wheels direction and have an turn assistant try to rotate the non steer wheels This will require 2 people wheels do not turn Plumb a 0 to 500 psi 35 bar gauge into the hose REVA Rebuild or replace the brakes OR replace the brake release valve item A OR consult the Genie Industries Service Department If machine still does not drive at full speed with the platform in the stowed position replace the platform controls OR replace the platform controls circuit board U3 OR replace the ECM U5 OR consult the Genie Industries Service Department Replace the shuttle valve item B OR from the function less than replace the brake manifold to the brake 200 psi release valve item A Attempt to drive the OR the function machine in either manifold or brake wheels direction and read the release man
149. i 241 3 Ln FUNCTION MANIFOLD PRESSURE TANK Y OLT e IMPORTANT NOTES ABBREVIATION LEGEND rm B rk Description Item Description n H BD Refer to Repair Procedure 6 3 Valve Adjustments BA Test port p NC SN Ae 5 Function Manifold for platform lift relief valve setting BB Flow regulator steer circuit E se pease BC Relief valve system ABBREVIATION LEGEND BD Relief valve lift foo MESH e puo eere Item Description BE Orifice washer steer circuit Check valve manual brake release BF Relief valve steer 8 B Shuttle valve brake release BG Platform up Hand pump manual brake release BH Check valve drive circuit D Platform lowering valve BI Steer left right E Orifice platform down circuit BJ Drive forward reverse F Accumulator BK Check valve steer circuit Part No 72876 Genie GS 1530 and GS 1930 6 37 April 2003 Section 6 Schematics M Hydraulic Schematic from serial number 35800 to 59999 Service Manual GS 1530 amp GS 1930 Part No 72876 Rev C2 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33
150. ifold may donot pressure on the gauge have an internal defect turn OR consult the Genie 200 to Industries Service 300 psi Department Pressure is good Replace the brakes OR consult the Genie Industries Service Department Plumb a 0 to 500 psi 35 Replace the shuttle bar gauge into the hose valve item B OR from the function less than replace the brake manifold to the brake 200 psi release valve item A Attempt to drive the OR the function machine in either manifold or brake direction and read the release manifold may pressure on the gauge have an internal defect OR consult the Genie 200 to Industries Service 300 psi Department Pressure is good Replace the brakes OR consult the Genie Industries Service Department 5 18 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA Drive Forward Function inoperative Be sure all other functions operate normally Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch Connect the positive turned to platform lead from a volt meter to controls and both the drive forward Emergency Stop buttons light is directional valve coil pulled out to the ON on item Al or BJ wire position activate drive terminal without controller in the forward disconnecting the wire direction and check to and the negative lead of see if the erro
151. il can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Component damage hazard Hoses can be damaged if they are kinked or pinched CAUTION 8 Support and secure the yoke assembly to an appropriate lifting device 9 Remove the retaining fastener from the steer link at the yoke assembly Note the quantity and location of the spacers when disconnecting the steer link from the yoke assembly 10 Remove the retaining fastener from the top of the yoke pivot shaft 11 Lower the yoke assembly out of the chassis Bodily injury hazard The yoke ACAUTION motor assembly may fall if not properly supported when it is removed from the chassis During re assembly be sure that the spacers are installed onto the steer link Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 STEER AXLE COMPONENTS How to Remove a Drive Motor 1 Block the non steer wheels 2 Center a lifting jack under the drive chassis at the steer end of the machine 3 Remove the cotter pin from the wheel castle nut of the motor to be removed Always replace the cotter pin with a new one when removing the castle nut 4 Loosen the wheel castle nut Do not remove it Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis could
152. in death or serious injury Remove all rings watches and other jewelry Part No 72876 Genie GS 1530 and GS 1930 4 3 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS 3 Locate the potentiometer on the base of the joystick controller ol n t m H L E U3 PLATFORM CONTROLS joystick controller JC1 potentiometer shaft potentiometer set screw platform controls circuit board U3 potentiometer R15 brown wire purple wire 7 o0oocoonrc 4 With a volt meter set to read DC voltage place the volt meter negative lead on the purple wire Place the volt meter positive lead on the brown wire AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry REV B 5 Loosen the set screw on the potentiometer shaft just enough to let the shaft rotate 6 With the joystick in the neutral position adjust the potentiometer to 2 05V DC at the potentiometer shaft Tighten the set screw 7 Move the joystick full stroke in both directions several times Return the joystick to the neutral position Result The volt meter should read 2 05V DC Result If the volt meter does not read 2 05V DC repeat steps 5 through 7 8 Turn
153. indicator GND Ground Horn or alarm H1 Horn H2 Automotive style horn option H5 Multifunction alarm JC1 Joystick controller KS1 Key switch LED or light L16 Lift L17 Drive L19 Power L25 Fault LS Limit switch LS6 Platform up down LS7 Pothole LS8 Pothole M5 Hydraulic power unit N C Normally closed N C H O Normally closed held open Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R15 5000 ohm potentiometer R21 75 ohm resistor Sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch Electronic component BL XL U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression WIRE COLOR LEGEND Color Description BL Blue Valve coil BK Black Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up BN Brown GN
154. ine on any slope it is able to climb 8 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 9 Locate the drive forward reverse valve on the function manifold Refer to Illustrations 2 Illustration 2 a drive forward reserve valve 3 12 Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures REVC 10 Tag the forward and the reverse valve coils Remove the coils from the valve The forward valve coil has white and brown wires attached The reverse valve coil has white black and brown wires attached For reassembly it will be helpful to leave the wire harness attached to the valve coils 11 Remove the drive forward reverse valve from the function manifold Cap the open port of the manifold 12 Carefully inspect the hex portion of the valve for an identification stamp Result SV10 4727 is stamped on the hex portion of the drive forward reverse valve This indicates the machine is equipped with a dynamic brake valve Proceed to step 13 W Result SV10 4727 is not stamped on the hex portion of the drive forward reverse valve This indicates the machine is not equipped with a dynamic brake valve Proceed to step 18 13 Install the drive forward reverse valve removed in step 11 into th
155. ion alarm Diagnostic display code 5 DIP switch code 01000000 Options motion beacon Diagnostic display code HAUT DIP switch code 00001100 Options overload cut out descent delay Diagnostic display code 07 DIP switch code 00010100 LLL Options lift drive cut out descent delay Diagnostic os DIP switch code 00100100 Options motion alarm descent delay Diagnostic display code DIP switch code 01000100 Options motion beacon descent delay Diagnostic display code 1 0 DIP switch code 00011100 Options lift drive cut out overload cut out descent delay Diagnostic display code GU DIP switch code 00101100 Options motion alarm overload cut out descent delay Diagnostic display code 2 HOME DIP switch code 01001100 Options motion beacon overload cut out descent delay Diagnostic display code 13 MUU DIP switch code 00110100 Options motion alarm lift drive cut out descent delay Diagnostic ee DIP switch code 01010100 Options motion beacon lift drive cut out descent delay Diagnostic display code 1 DIP switch code 01100100 Options motion beacon motion alarm descent delay Section 4 Repair Procedures SSS SSS SS Diagnostic display code 16 WOOO DIP switch code 00111100 Options motion alarm lift drive cut out overload cut out desce
156. ir Procedures REV B 11 Repeat steps 5 through 7 to confirm the relief valve pressure 12 Place maximum rated load into the platform Secure the load to the platform Refer to Section 2 Specifications 13 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 14 Hold the lift relief valve with a wrench and remove the cap item BD 15 While activating the platform up function adjust the internal hex socket clockwise just until the platform begins to raise 16 Fully lower the platform 17 Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight 18 Raise the platform slightly Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the adjustment is correct 19 Install the relief valve cap 20 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or the platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic tank Component damage hazard Do CAUTION not continue to operate the machine if the hydraulic pump is cavitating FUNCTION MANIFOLD Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 FUNCTION MANIFOLD REV How
157. ircuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap CAUTION 4 Carefully disconnect the three wire harness connectors from the platform controls circuit board 5 Carefully remove the platform controls circuit board retaining fasteners 6 Carefully remove the platform controls circuit board from the platform control box lid PLATFORM CONTROLS 1 2 Joystick Controller Maintaining the joystick at the proper setting is essential to safe machine operation The joystick should operate smoothly over its entire range of motion A Hall effect joystick controller was incorporated into the platform controls after serial number 51014 It does not require any calibration How to Calibrate the Joystick Controller before serial number 51015 This procedure applies only to models with a potentiometer equipped joystick 1 Turn the key switch to platform controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result
158. ith an oil filter wrench 2 Applyathin layer of oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Usea permanent ink marker to write the date and number of hours from the hour meter if equipped on the filter 5 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Activate and hold the platform up toggle switch 7 Inspect the filter and related components to be sure that there are no leaks 8 Clean up any oil that may have spilled Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures REVC B 11 Check the Module Tray Latch Components Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition Models before serial number 35800 1 Open both module trays and lubricate each module tray latch Using light oil apply a few drops to the side of the latch pin 2 Inspect each module tray latch pad if equipped Replace any worn pad before the latch fails to securely hold the module tray closed The module tray latch pad is attached to the drive chassis and located above the module tray latch when the module tray is closed CHECKLIST
159. just if needed 9 Install the cable mounting nut onto the lowering valve 10 Raise the platform and rotate the safety arm to the stowed position 11 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly Part No 72876 Genie GS 1530 and GS 1930 4 35 Section 4 Repair Procedures April 2003 GROUND CONTROLS 4 2 Toggle Switches Toggle switches used for single function switching are single pole double throw SPDT switches How to Test a Single Pole Double Throw Toggle Switch Continuity is the equivalent of 0 to 3 ohms A simple continuity tester may not accurately test the switch This procedure covers fundamental switch testing and does not specifically apply to all varieties of toggle switches 1 Turn the key switch to the orr position Tag and disconnect all wiring from the toggle switch to be tested Disconnect the wires from the toggle switch before testing REV B 2 Connect the leads of an ohmmeter to the switch terminals in the following combinations listed below to check for continuity Left Center Right 1 3 2 2 2 Test Left position Desired result terminal 1 to 2 3 no continuity infinite Q terminal 2 to 3 continuity zero Center position Right position There are no terminal combinations that will produce continuity infinite W terminal 1 to 2 continuity zero termina
160. ker SW6 horn button BN5 machine on incline button lift function select button BN9 drive function select BN8 red Emergency Stop button P2 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Press the drive function select button Result The diagnostic display will show PS REV B 6 Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage 7 Usethe steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Specifications 8 Turn the key switch to the off position Any change in software settings will not take effect until the key Switch is turned to the off position A 1 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B PLATFORM CONTROLS Software revision DO and higher 6 Use the steering thumb rocker switch on the joystick to increase or decrease the maximum 1 Push in the red Emergency Stop button to the lift speed percentage Refer to Section 2 off position at the ground and platform controls Specifications N 5 A Turn the key switch to the off position 7 Turn the key switch to the off position Pull out the red Emergency Stop button to the on position at the ground and platform controls Press and hold
161. l ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 72876 Genie GS 1530 and GS 1930 4 1 Section 4 Repair Procedures April 2003 Platform Controls The platform controls used to operate the machine from the platform or while standing on the ground can also be used to tune the performance of the machine Moving the joystick or activating a button or toggle switch sends a signal to the Electronic Control Module ECM When the ECM is in the function mode the platform controls are used to operate the various machine functions When the ECM is in the programming mode PS is shown in the diagnostic display window the platform controls are used to adjust the function speed parameters The platform controls contains an electronic circuit board joystick membrane decal buttons switches and LEDs Potentiometer equipped joysticks can be adjusted to maintain performance For further information or assistance consult the Genie Industries Service Department REV P2 EMERGENCY STOP BUTT
162. l 1 to 3 no continuity infinite Q terminal 2 to 3 no continuity 4 36 Genie GS 1 530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 4 3 Control Relays Relays used for single function switching are single pole double throw SPDT relays How to Test a Single Pole Double Throw Relay AWARNING Electrocution hazard Contact with electrically charged circuits could cause death or serious injury Remove all rings watches and other jewelry 1 Label and then disconnect all the wiring from the relay to be tested 2 Connectthe leads from an ohmmeter or continuity tester to each terminal combination and check for continuity Terminals 85 and 86 represent the coil and should not be tested in any other combination Test Desired result terminal 85 to 86 with resistor 310 to 3300 terminal 87 to 87a and 30 no continuity infinite Q terminal 87a to 30 continuity zero Q GROUND CONTROLS 3 Connect 24V DC and a ground wire to terminals 85 and 86 then test the following terminal combinations Test Desired result terminal 87a to 87 and 30 no continuity infinite Q terminal 87 to 30 continuity zero Q Terminal Number Legend terminal no 87a N C terminal no 85 ground terminal no 30 common terminal no 86 coil terminal no 87 N O Part No 72876 Genie GS 1530 and GS 1930 Section
163. lace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure ie fasteners intended for one PASS time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time oy Be sure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area m is properly ventilated and well lit Vala iv Genie GS 1530 and GS 1930 Part No 72876 April 2003 Introduction Section One Section Two Section Three Table of Contents limiPOrtant MPO MMMALIOMN pL li Safety Rules General Safety Rules esssssssssssssesesee eene ener nennen rinse nnne nns iii Specifications Rev C Machine Specifications GS 1530 ssssssssssssssssseeeeeeeenen nennen 2 1 Performance
164. lace blocks under the chassis for support AWARNING Crushing hazard The chassis could fall if not properly supported April 2003 REV B 7 Turn the yokes to the side so the bellcrank can be removed 8 Remove the bellcrank from the machine Note the quantity and the location of the spacers in between the bellcrank and the steer links Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 9 1 Drive Brake How to Remove a Drive Brake When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Support and secure the entry ladder to an appropriate lifting device 2 Remove the entry ladder mounting fasteners Remove the entry ladder from the machine Crushing hazard The entry ladder ACAUTION may become unbalanced and fall if itis not properly supported and secured to the lifting device 3 Block the steer wheels 4 Center a lifting jack under the drive chassis at the non steer end 5 Remove the cotter pin from the wheel castle nut Always replace the cotter pin with a new one when removing the castle nut 6 Loosen the wheel castle nut Do not remove it Non steer Axle Components 7 Raisethe machine approximately 2 inches 5 cm Place blocks under the chassis for support Crushin
165. lic fluid during operation It utilizes internal suction strainers for the pump supply lines and has an external return line filter How to Remove the Hydraulic Tank Component damage hazard The CAUTION work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications Perform this procedure with the platform in the stowed position 1 Disconnect the battery pack from the machine AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry REVA 2 Open the power unit module tray 3 Remove the drain plug from the hydraulic tank and allow all of the oil from the tank to drain into a suitable container Refer to Section 2 Specifications AWARNING P ily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Tag disconnect and plug the hydraulic tank return hose at the top of the hydraulic tank Remove the motor controller mounting bracket retaining fasteners and move the motor
166. lift cylinder index 15 13 Remove the pin retaining fasteners from the cylinder rod end pivot pin index 3 Use a soft metal drift to remove the pin Bodily injury hazard The cylinder ACAUTION may fall if not properly supported when the pin is removed 14 Lower the lift cylinder index 15 onto the number 1 center pivot pin index 8 15 Attach a lifting strap from an overhead crane to the number 3 inner arm index 12 16 Remove the external snap rings from the number 3 pivot pin index 4 17 Use a soft metal drift to remove the number 3 pivot pin index 4 Remove the number 3 inner arm index 12 from the machine Bodily injury hazard The number ACAUTION 3 inner arm index 12 may become unbalanced and fall if not properly supported when it is removed from the machine 18 Attach a lifting strap from an overhead crane to the number 2 outer arm index 16 19 Remove the external snap rings from the number 2 center pivot pin index 5 at the battery pack side of the machine 20 Use a soft metal drift to remove both of the number 2 center pivot pins index 5 REVA 21 Remove the external snap rings from the number 2 pivot pin index 17 at the non steer end 22 Use a soft metal drift to remove the number 2 pivot pin index 17 Remove the number 2 outer arm index 16 from the machine Bodily injury hazard The number ACAUTION 2 outer arm index 16 may become unbalanced and fall if not
167. lled with the X on the level sensor base closest to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to install the tilt level sensor as instructed could MEM cause the machine to tip over resulting in death or serious injury 17 Install the level sensor box onto the machine Install the level sensor box retaining fasteners 18 Connect the wiring harness to the level sensor limit switch and alarm 19 Turn the key switch to the ground control and pull out the red Emergency Stop button to the ON position at the ground controls Non steer end scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 GROUND CONTROLS 20 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound Be sure there are threads showing through the top of the adjusting fasteners 21 Raise the platform slightly 22 Return the safety arm to the stowed position 23 Lower the platform to the stowed position 24 Raise the machine approximately 2 inches 5 cm 25 Remove the blocks from under both wheels 26 Lower the machine and remove the jack 27 Remov
168. lt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to install the tilt level sensor as instructed could cause the machine to tip over resulting in death or serious injury MEM Non steer end scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener Part No 72876 Genie GS 1530 and GS 1930 4 51 Section 4 Repair Procedures April 2003 12 Install the level sensor box onto the machine Install the level sensor box retaining fasteners 13 Connect the wiring harness to the level sensor limit switch and alarm 14 Turn the key switch to the ground control and pull out the red Emergency Stop button to the ON position at the ground controls 15 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound Be sure there are threads showing through the top of the adjusting fasteners 16 Raise the platform slightly 17 Return the safety arm to the stowed position 18 Lower the platform to the stowed position 19 Center a lifting jack under the drive chassis at the ground controls side of the machine 20 Raise the machine approximately 2 inches 5 cm 21 Place a 0 85 x 6 x 6 inch 21 6 mm x 15cm x 15 cm thick steel block under both wheel
169. m a scheduled inspection Inspection Table or Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Annually or every 1000 hours A B C Two year or every 2000 hours A B C D Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms as required 3 2 Genie GS 1530 and GS 1930 Part No 72876 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie Genie Industries USA 18340 NE 76th Street PO Box 97030 Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH Engla
170. mber 3 pivot pin non steer end 20 Number 2 inner arm 21 Number 2 outer arm 22 Number 2 pivot pin non steer end 23 Lift cylinder barrel end pivot pin 24 Number 1 outer arm 4 24 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 3 2 Scissor Assembly GS 1930 How to Disassemble the Scissor Assembly GS 1930 AWARNING 2 dlily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section Two Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the cables from the side of the number 4 outer arm index 15 at the ground controls side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched SCISSOR COMPONENTS 3 Attach a lifting strap from an overhead crane to the number 4 outer arm index 15 4 Remove the external snap rings from the number 4 center pivot pin index 2 5 Use a soft metal drift to remove the number 4 center pivot pin index 2 6 Remove the external sna
171. n or maintenance information Indicates that a specific result is expected after performing a series of steps Part No 72876 Genie GS 1530 and GS 1930 3 1 Section Scheduled Maintenance Procedures April 2003 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appears at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Indicates that dealer service will be requiredto perform this procedure Bio amp Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation Report to use for each inspection Store completed forms as required Maintenance Schedule There are four types of maintenance inspections that must be performed according to a schedule daily quarterly annual and two year The Scheduled Maintenance Procedures Sectionand the Maintenance Inspection Reporthave been divided into four subsections A B C and D Use the following chart to determine which group s of procedures are required to perfor
172. nd 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries RevA Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures April2003 ET This page intentionally left blank 3 4 Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A Rev C Y NR Checklist B Rev Y NR A 1 Pre operation inspect Serial number P P B 1 Batteries A 2 Function tests Date Perform after 40 hours B 2 Electrical wiring B 3 Tires and wheels A 3 30 d
173. nds Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port SAE O ring Boss Port tube fitting installed into Aluminum tube fitting installed into Steel SAE Dash size Torque SAE Dash size Torque 4 11 ft lbs 14 9 Nm 4 16 ft lbs 21 7 Nm 6 23 ft lbs 31 2 Nm 6 35 ft lbs 47 5 Nm 8 40 ft lbs 54 2 Nm 8 60 ft lbs 81 3 Nm 10 69 ft lbs 93 6 Nm 10 105 ft Ibs 142 4 Nm 12 93 ft lbs 126 1 Nm 12 140 ft Ibs 190 Nm 16 139 ft Ibs 188 5 Nm 16 210 ft lbs 284 7 Nm 20 172 ft lbs 233 2 Nm 20 260 ft lbs 352 5 Nm 24 208 ft lbs 282 Nm 24 315 ft lbs 427 1 Nm Seal Loke Fittings JIC 37 Fittings hose end swivel nut or hose connection SAE Dash size Torque SAE Dash size Thread Size Flats 4 18 ft lbs 24 4 Nm 4 7 16 20 2 6 27 ft lbs 36 6 Nm 6 9 16 18 1 1 4 8 40 ft lbs 54 2 Nm 8 3 4 16 1 10 63 ft lbs 85 4 Nm 10 7 8 14 1 12 90 ft lbs 122 Nm 12 1 1 16 12 1 16 120 ft lbs 162 7 Nm 16 1 5 16 12 1 20 140 ft lbs 190 Nm 20 1 5 8 12 1 24 165 ft lbs 223 7 Nm 24 1 7 8 12 1 2 6 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 2 Specifications REV SPECIFICATIONS Torq ue Procedure 3 Working clockwise on the body hex fitting
174. ning fasteners and move the motor controller to the side Remove the return filter mounting bracket fasteners from the manifold Push the filter and accumulator out of the way Tag disconnect and plug the hydraulic pump inlet hose at the side of the hydraulic tank Remove the hydraulic tank retaining fasteners and remove the hydraulic tank from the machine Remove the suction strainer from the tank and clean it using a mild solvent 10 Clean the inside of the hydraulic tank using a mild solvent 11 Install the suction strainer using thread sealer on the threads Part No 72876 Genie GS 1530 and GS 1930 3 19 Section Scheduled Maintenance Procedures April 2003 CHECKLIST D PROCEDURES 12 Install and tighten the hydraulic tank drain plug using thread sealer on the threads Torque to specification Torque specifications Hydraulic tank drain plug dry 75 in Ibs 8 5 Nm Hydraulic tank drain plug lubricated 56 in Ibs 6 3 Nm 13 Install the hydraulic tank and install and tighten the hydraulic tank retaining fasteners Torque to specification Torque specifications 70 in Ibs 7 9 Nm Hydraulic tank retaining fasteners dry Hydraulic tank retaining fasteners lubricated 52 in Ibs 5 9 Nm 14 Install the hydraulic pump inlet hose onto the fitting at the side of the hydraulic tank and tighten the hose clamp 15 Install the hydraulic filter bracket and the motor controller bracket
175. nt delay Diagnostic display code 7 HOTO DIP switch code 01011100 Options motion beacon lift drive cut out overload cut out descent delay Diagnostic display code OOL DIP switch code 01101100 Options motion beacon motion alarm overload cut out descent delay Diagnostic display code DIP switch code 01110100 Options motion beacon motion alarm lift drive cut out descent delay Diagnostic display code 20 DIP switch code 01111100 Options motion beacon motion alarm lift drive cut out overload cut out descent delay Diagnostic display code at MUU HL DIP switch code 00011000 Options lift drive cut out overload cut out Diagnostic display code 22 HU DIP switch code 00101000 Options motion alarm overload cut out Diagnostic display code DIP switch code 01001000 Options motion beacon overload cut out PLATFORM CONTROLS DIP switch code 00111000 Options motion alarm lift drive cut out overload cut out zo DIP switch code 01011000 Options motion beacon lift drive cut out overload cut out Diagnostic 26 HOU DIP switch code 01101000 Options motion beacon motion alarm overload cut out aed Vang nel DIP switch code 01111000 Options motion beacon motion alarm lift drive cut out overload cut out seo DIP switch code 00110000 Options motion alarm lift drive cut out Dia
176. oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 48 Tag and disconnect the wires and manual lowering cable from the solenoid valve on the cylinder 49 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 8 Raise the lift cylinder to a vertical position Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REVA 50 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 23 Use a soft metal drift to remove the pin Remove the lift cylinder index 8 from the machine AWARNING Crushing hazard The lift cylinder index 48 may become unbalanced and fall when it is removed from the machine if not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 51 Place a 4 x 4 x48 inch 10 cm x 10 cm x 1 2 m long block across both sides of the chassis under the number 1 center pivot pin index 10 CAUTION 52 Attach a lifting strap from an overhead crane to the number 1 inner arm index 11 at the non steer end Raise the number 1 inner arm and remove the safety arm Lower the number 1 inner arm index 11 onto the block that was placed across the chassis Bodily injury hazard Keep hands
177. ole arm activates the switch OR replace the limit switch contact OR replace the LS8 Chart 13 Raise the platform to more than 6 feet 1 8 m and drive the machine If the machine does not drive and an alarm sounds the machine is operating normally Check the pothole guards for obstructions OR test the pothole guard limit switches See Repair section Part No 72876 Genie GS 1530 and GS 1930 5 21 Section 5 Troubleshooting Flow Charts April 2003 Chart 14 REVA Machine light is not on With the key switch Check limit switch LS7 Check the controller Drives At Full Speed With turned to platform controls and both Emergency Stop buttons pulled out to the and 158 for correct adjustment adjustments See Repair Section OR replace the platform controls OR replace the Platform position and the platform ECM U5 OR consult the In the stowed position Genie Industries Service Raised drive the machine in Adjust LS7 or LS8 See Department Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected either direction Is the error indicator light on at the platform controls See Chart 13 OR remove the obstruction from the pothole guard OR consult the Genie Industries Service Department Repair Section OR repair or replace limit switch wire circuit Genie GS 1530 and GS 1930 Part No 728
178. ols PS2 Platform overload pressure switch option QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to ground QD4 Control cable to platform Resistor R15 5000 ohm potentiometer R21 75 ohm resistor sw Switch SW5 Function enable SW6 Steer left right SW25 DIP switches 57 Tilt level sensor TS66 Platform up down toggle switch Electronic component U3 Encoder printed circuit board U5 Electronic control module U6 Motor controller U9 Battery charger U13 Voltage inverter option U27 47 mH inductor noise suppression BL YE WIRE COLOR LEGEND Color Description Valve coil BL Blue Y2 Brake release Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up BK Black BN Brown GN Green OR Orange RD Red WH White YL Yellow GROUND DATA LINK HIGH DATA LINK LOW JC1 Joystick CONTROLLER WH YL 5000 OHM SW 6steer SW25 POTENTIOMETER ele DIP SWITCHES 2 FUNCTION 07 VOLTAGE REGULATOR POUT POWER LED L19 3 POUT2 O FAULT LED L25 POUT3 HIGH TORQUE LED L21 POUT4 BATTERY LEVEL1 POUTS BATTERY LEVEL2 POUT6 O BATTERY LEVEL3 gt 37 POUT7 BATTERY LEVEL4
179. on jerking and unusual noise Hydraulically released individual wheel brakes can appear to operate normally when not fully operational Perform this procedure with the machine on a firm level surface that is free of obstructions Be sure the platform extension deck is fully retracted and the platform is in the stowed position 1 Mark atest line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Lower the platform to the stowed position Press the drive function select button Refer to Illustration 1 so Genie Illustration 1 a drive function select button BN8 5 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the test line REVC 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line 7 Measure the distance between the test line and your machine reference point Refer to Section 2 Specifications Result The machine stops within the specified braking distance No action required amp Result The machine does not stop within the specified braking distance Proceed to step 8 and determine if the machine is equipped with a dynamic braking valve The brakes must be able to hold the mach
180. orklift at the non steer end Do not apply any lifting pressure 8 Attach a strap from the platform railings to the carriage on the forklift to help support the platform 9 Remove the platform pivot pin retaining fasteners from the platform pivot pins at the steer end of the machine 10 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall if not properly supported 11 Remove the plugs from the access holes in the side of the platform 12 Lift the steer end of the platform slightly to clear the scissor arms and slide the platform towards the non steer end of the machine until the non steer end platform pivot pins are visible through the access holes in the side of the platform 13 Remove the platform pivot pin retaining fasteners from the platform pivot pins at the non steer end of the machine 14 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall if not properly supported 15 Carefully lift the platform off of the machine and place it on a structure capable of supporting it Note the position of the wear pads before the platform is removed so when the platform is installed they will be in the correct position Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures eee REVA PLATFORM COMPONENTS 2 2 7 Remove the platform roller wheels from the machine Platform Extension 8 Carefully slide the platform
181. orm 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Push the handle on the manual platform lowering cable all the way in REV B 5 Disconnect the cable mounting nut from the lowering valve at the barrel end of the lift cylinder a manual lowering cable sheath b upper lock nut c cable mounting bracket d lower lock nut e cable mounting nut f end of the lowering cable g manual lowering valve schematic item D 6 Pullthe cable tight and measure the distance between the end of the lowering cable and the end of the lowering valve Result The measurement should be 3 16 to 1 4 inch 4 7 to 6 4 mm Platform manual lowering cable specification 3 16 to 1 4 inch 4 7 to 6 4 mm Gap lowering cable to valve Skip to step 10 if the measurement is correct 4 34 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures Eee EEE REV B GROUND CONTROLS 7 To adjust loosen the upper lock nut on the cable mounting bracket Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance 8 Tighten the upper lock nut and re measure the distance between the end of the lowering cable and the end of the lowering valve Re ad
182. p function adjust the internal hex socket clockwise just until the platform begins to raise 9 Fully lower the platform 10 Add an additional 50 pounds 22 7 kg to the platform Secure the additional weight 11 Raise the platform slightly Result The power unit should not be able to lift the platform Result If the power unit lifts the platform adjust the internal hex socket counterclockwise until the adjustment is correct 12 Install the relief valve cap Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 13 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic reservoir Component damage hazard Do CAUTION not continue to operate the machine if the hydraulic pump is cavitating After serial number 35799 1 Open the hydraulic power unit module tray and locate the system relief valve on the function manifold item BC c ES e SP b SZ m BD e BE SB ale Wi di S RC Ro Nx BG Sus BH BK a ve BI a test port b system relief valve c function manifold 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold item BA FUNCTION MANIFOLD 3 Chock both sides of the wheels
183. p ring from the number 4 pivot pin index 16 at the non steer end of the machine 7 Usea soft metal drift to remove the number 4 pivot pin index 16 from the non steer end of the machine Remove the number 4 outer arm index 15 from the machine Crushing hazard The number 4 ACAUTION outer arm index 15 may become unbalanced and fall if not properly supported when it is removed from the machine 8 Remove the cables from the upper cable tray and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 9 Remove the mounting fasteners from the upper cable tray supports 10 Remove the upper cable tray from the scissor assembly 11 Attach a lifting strap from an overhead crane to the number 4 inner arm index 14 12 Remove the external snap rings from the number 4 pivot pin index 3 Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS 13 Use a soft metal drift to remove the number 4 pivot pin index 3 at the steer end Remove the number 4 inner arm index 14 from the machine Crushing hazard The number 4 ACAUTION inner arm index 14 may become unbalanced and fall if not properly supported when it is removed from the machine 14 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the ground controls side 15 Remove the external snap rings from the n
184. penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Identify us Troubleshoot discovered symptoms problem Still exists Return to Y Perform service problem repair solved Part No 72876 Genie GS 1530 and GS 1930 6 1 Section 6 Schematics April 2003 Electrical Components REV Item Description Genie Part Manufacturer Manufacturer Qty Number Part Number Battery 225AH 6V DC 62201 Trojan Battery Co T 105 diy uie 4 unes Circuit breaker 7A 47811 EDA H 45 700 IG1 P10 1 Relay 24V DC before serial number 43737 56302 Potter Brumfield VF4 15H11 CO5 1 after serial number 43736 78098 Siemens VF4 45H11 CO5 1 CRAB Relay 24V DC before serial number 43737 56302 Potter Brumfield VF4 15H11 CO5 1 after serial number 43736 78098 Siemens innere VF4 45H11 CO5 1 I Oiseau decens Fuse 275A 40833 BUSS icr otn er ron 275
185. ponents after serial number 35799 components 6 35 Genie GS 1530 and GS 1930 Part No 72876 Brake release hand pump manifold con ee m 0 Lift cylinder components before serial number 23568 t Lift cylinder components after serial number 23567 Filter e Fixed displacement pump Q Bi directional motor M Variable speed motor ruis Solenoid operated 3 position 4 way directional valve LL e Nv Solenoid operated 2 position 2 way directional valve mn cm Relief valve IA ar Te Priority flow regulator 0 040 1 Orifice with size QNn Check valve LES Dual acting cylinder PT Solenoid operated 2 position 2 way valve normally closed with manual over ride Y8 gt Solenoid operated 2 position 4 way directional valve Check valve pilot to open ODE Shuttle valve Hand pump Single acting cylinder 1 03 CU IN 16 9 cc Accumulator April 2003 Section 6 Schematics SSS
186. r hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury Tip over hazard This procedure A DANGER must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Software revision AO and 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at both the ground and platform controls REV 3 Press and hold the lift function enable and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS A N a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 horn button BN5 machine on incline button lift function enable button BN9 red Emergency Stop button P2 O Release the lift function enable and horn buttons Press and hold the lift function enable button Result The diagnostic display will show the maximum lift speed percentage Use the steering thumb rocker switch on the joystick to increase or decrease the maximum lift speed percentage Refer to Section 2 Sp
187. r indicator the volt meter to the light at the platform brown ground wire on controls is on the coil Activate drive in the forward direction and check the voltage Disconnect the wires from the drive forward directional valve coil item Al or BJ and check resistance of the coil See Repair Section light is not on Repair or replace the drive forward directional valve item Al or BJ OR consult the Genie Industries Service Department Check the connection at the ECM U5 OR replace the drive forward reverse valve cartridge item Al or BJ OR consult the Genie Industries Service Department 20V or more 18 to 20 ohms Chart 11 Repair open in the WH C6 fwd coil wire from the drive forward directional valve coil item AI or BJ to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Replace the drive forward directional valve coil item Al or BJ Part No 72876 Genie GS 1530 and GS 1930 5 19 Section 5 Troubleshooting Flow Charts April 2003 Chart 12 REVA Drive Reverse With the key ils Connect the positive Repair open in the WH 1 turned to platform lead from a volt meter to A7 rev coil wire from the Function controls the drive reverse drive reverse directional 1 Emergency Stop buttons ias directional valve coil valve coil item Al or BJ Inoperative pulled out
188. rake release Y3 Steer right Y4 Steer left Y5 Drive reverse Y6 Drive forward Y7 Platform down Y8 Platform up J H rc c BK POWER TO PLATFORM CONTROLS A A RD POWER TO GROUND CONTROLS a B B WH GROUND AC D D BL DATA LINK HIGH E E YL DATA LINK LOW QD3 blc nm J WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN Green OR Orange RD Red WH White YL Yellow Pr rs rs DIP SWITCHES 9 QD 24V DC 8 D7 VOLTAGE 0 REGULATOR POUT1 POUT2 O POUT3 POUT4 POUTS POUT6 POUT7 POUT8 O POUT9 POUT10 C U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD POUT11 from serial number 21263 to 25141 D _ P2 EMERGENCY STOP 1 JC1 Joystick CONTROLLER WHYL 5000 OHM POTENTIOMETER 2 SW5 s FUNCTION ENABLE POWER LED L19 3 4 FAULT LED L25 4 HIGH TORQUE LED L21 4 BATTERY LEVEL 1 4 BATTERY LEVEL 2 4 BATTERY LEVEL 3 G7 BATTERY LEVEL4 4 BATTERY 5 4 DRIVE LED L17 4 LIFT LED L16 PLATFORM CONTROLS MEMBRANE DECAL PANEL 4 HIGH TORQUE BN6 4 HORN BN5 5 DRIVE ENABLE BN8 LIFT ENABLE BN9 6 PLATFORM CONTROLLER f 8 Part No 72876 Genie GS 1530 and GS 1930 6 18 April 2003 Section 6 Schematics SSeS See Electrical Schematic from
189. range Y5 Drive reverse PP Purple Y6 Drive forward RD Red Y7 Platform down WH White Y8 Platform up YL Yellow PIO2 24V DC VOLTAGE REGULATOR 6 6 SW25 DIP SWITCHES POUT1 POUT2 C POUT3 POUT4 POUTS POUT6 POUT7 POUT8 POUT9 O POUT10 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD PIN1 PIN2 PIN3 PIN4 PINS PIN8 Section 6 Schematics I Electrical Schematic PIN10 POUT11 from serial number 52967 to 53999 D P2 EMERGENCY STOP 1 JOYSTICK GENERATOR CONTROLLER 151 6 STEER LEFT RIGHT Pp per 2 m 4 SW5 FUNCTION 3 POWER LED L19 FAULT LED L25 HIGH TORQUE LED L21 BATTERY LEVEL 1 BATTERY LEVEL2 4 BATTERY LEVEL 3 gt G7 BATTERY LEVEL4 BATTERY LEVEL 5 DRIVE LED L17 LIFT LED L16 PLATFORM CONTROLS MEMBRANE DECAL PANEL 5 HIGH TORQUE BN6 HORN BN5 DRIVE ENABLE BN8 LIFT ENABLE BN9 6 CONTROLLER 8 Part No 72876 Genie GS 1530 and GS 1930 6 32 April 2003 Section 6 Schematics dl Electrical Schematic from serial number 52967 to 53999 Section 6 Schematics April 2003 E Electrical Schematic REV from serial number 54000 to 59999
190. res and manual lowering cable from the solenoid valve on the cylinder 31 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder index 15 Raise the lift cylinder to a vertical position SCISSOR COMPONENTS 32 Remove the pin retaining fasteners from the lift cylinder barrel end pin index 18 Use a soft metal drift to remove the pin Remove the lift cylinder index 15 from the machine AWARNING Crushing hazard The lift cylinder index 15 may become unbalanced and fall when it is removed from the machine if it is not properly attached to the overhead crane Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine CAUTION 33 Place a 4 x 4 x 32 inch 10 x 10 x 80 cm long block across both sides of the chassis under the number 1 center pivot pin index 8 34 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 Raise the inner arm slightly and remove the safety arm Lower the arms onto the block Bodily injury hazard Keep hands ACAUTION clear of moving parts when lowering the arms onto the block 35 Remove the cables from the number 1 inner arm index 9 and lay them off to the side Component damage hazard CAUTION Cables can be damaged if they are kinked or pinched 36 Attach a lifting strap from an overhead crane to the number 1 outer arm index 19 Do not lift i
191. ril 2003 SCISSOR COMPONENTS 3 3 Lift Cylinder How to Remove the Lift Cylinder AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform 7 to 8 feet 2 1 to 2 4 m 2 Liftthe safety arm move it to the center of the Scissor arm and rotate down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Tag and disconnect the wiring from the solenoid valve at the barrel end of the lift cylinder REVA Before serial number 23568 02 0 Q lt SJ Nu Sk 9 6 a lift cylinder b lowering cable solenoid valve schematic item D d cable mounting bracket e spring f orifice schematic item E g connector fitting h hydraulic hose i hard line assembly After serial number 23567 Z e 5 69 000 69 Genie GS 1530 and
192. rm down Y8 Platform up gt BK POWER TO PLATFORM CONTROLS pt A 3 RD POWER TO GROUND CONTROLS 1 I B WH GROUND RA D BL DATA LINK GENERATOR JOYSTICK E YL DATA LINK CONTROLLER VOLTAGE QD3 REGULATOR K ES 1 p SW6 STEER LEFT RIGHT 6 1 pee 2 2 SW5 eara FUNCTION oe 5 7 6 e 91 25 8 DIP SWITCHES POUTI POWER LED L19 POUT2 FAULT LED L25 POUT3 HIGH TORQUE LED 121 POUT4 BATTERY LEVEL 1 POUTS BATTERY LEVEL 2 4 POUT6 BATTERY LEVEL3 gt 37 POUT7 BATTERY LEVEL 4 POUT8 BATTERY LEVEL 5 POUT9 O z DRIVE LED L17 POUT10 O LIFT LED L16 op PLATFORM CONTROLS PRINTED CIRCUIT BOARD MEMBRANE DECAL PANEL 5 PIN1 HIGH TORQUE BN6 PIN2 HORN BN5 PINS _ DRIVE ENABLE BN8 PIN4 LIFT ENABLE BN9 PINS 6 PINS PIN10 POUTI1 CONTROLLER Color Description BL Blue BK Black BN Brown 8 GN Green GY Gray OR Orange PP Purple RD Red WH White YL Yellow Part No 72876 Genie GS 1530 and GS 1930 6 30 April 2003 Section 6 Schematics ed Electrical Schematic from serial number 51015 to 52966 Section 6 Schematics April 2003 E Electrical Schematic REV from serial number 52967 to 53999
193. rtment REVA Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts EVA Chart 4 Ground With key switch turned a ae in WH wire to ground controls and rom KS1 to Emergency Controls Emergency Stop Stop button P1 OR j uttons pulled out to the repair or replace P1 OR Inoperative a position check a open in WH wire voltage on the ground rom P1 to circuit Platform control contact at the breaker CB2 Controls input side of the key switch KS1 Operate Normally 20V or more Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are properly connected Be sure the batteries are fully charged Check if internal cam at KS1 is activating the ground control contact Check voltage on output side of ground control contact at KS1 20V or more Replace 51 Check voltage on the center terminal of the platform up down toggle switch TS66 at the ground controls Repair open in WH wire jumper from KS1 to the center terminal at TS66 20V or more Test or replace TS66 See Repair Section OR repair open in the WH B12 UP DWN SWITCH uP wire from TS66 to the ECM U5 OR repair open in the WH A12 UP DWN SWITCH DWN wire from TS66 to U5 OR consult the Genie Industries Ser
194. s 2 OPTION c 6 z z E 0 gt gt 9 Q 9 5 I T pg ni 2 9 g g 5 g 3 wm 2 LEVEL gt r 2 SENSOR 9 2 E E 3 P d o d amp 91 CIRCUIT R21 8 8 o 5 8 m 5 55 El 2 BOARD e s I 1 75 OHM gt 3 9 gt S ic E S t T o U27 e m z 2 E S7 47 mH n 3 LEVEL INDUCTOR 5 SENSOR QD1 9 M m g E rs c SENSOR 5 f SUPPRESSION r BN F6 MS 275A FUSE _ _ 2E _ B8 A9 A12 B12 11 c12 B9 A10 B10 C2 A4 Bii A2 Bi Ci Cii A5 OUT OUT OUT N IN IN IN OUT IN IN IN IN IN IN IN IN IN OUT Y a1 our U5 6 U9 ELECTRONIC CONTROL MODULE BATTERY CHARGER OUT OUT OUT OUT OUT OUT OUT OUT BS B3 C9 C7 B7 A7 C6 B6 A6 D es a SS RR a m i rn 3 Lr AC INPUT M S pii T y 4 6V T x BATTERY 2 g 9 x 9 9 3 5 3 3 E o 4 o 3 Q ee 8 5 o o 7 mE F8 SIDE 8 8 9 8 8 50A FUSE U6 motor 3 1 E m d CONTROLLER FB Z i nus ie G6 h 6 FB H2 Y2 Y4 Y5 Y6 Y7 Y8 f U13 HOUR FLASHING AUTOMOTIVE STYLE BRAKE STEER STEER DRIVE DRIVE PLATFORM PLATFORM 1 DC AC INVERTER METER BEACONS HORN RELEASE RIGHT LEFT REVERSE
195. s at the ground controls side of the machine 22 Lower the machine onto the blocks 23 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should not sound Result The tilt sensor alarm does sound Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 24 Lower the platform to the stowed position 25 Raise the machine approximately 2 inches 5 cm 26 Remove the blocks from under both wheels 27 Lower the machine and remove the jack 28 Center a lifting jack under the drive chassis at the battery pack side of the machine 29 Raise the machine approximately 2 inches 5 cm 30 Place a 0 98 x 6x 6 inch 24 9 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 31 Lower the machine onto the blocks Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures 32 Models before serial number 48817 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should sound O Result The tilt sensor alarm does not sound Adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted CE models When the platform is raised 7 to 8 feet 2 1 to 2 4 m from the ground an alarm should sound and the lift and drive functions should not operate Models after serial number 48816 Raise the platform 7 to 8
196. s not on Activate the function enable switch and activate the steer right no function Does the motor turn on yes Continued on the next page Connect the positive lead from a volt meter to the WH B7 left coil wire terminal at the steer left directional valve coil item AF or BI without oV disconnecting the wire and the negative lead of the volt meter to the brown ground wire at the valve coil Activate the steer rocker switch in the LEFT direction and check the voltage 20V or more Disconnect the wires from the coil on the 25 to 27 steer right directional ohms valve on the function manifold item AF or BI and check the resistance of the valve coil See Repair Section 0 or infinite ohms Replace the steer right directional valve coil item AF or BI Check continuity of the steer left right microswitch SW6 inside the joystick controller handle JC1 good Repair or replace the wire circuit from SW6 to the platform controls circuit board U3 OR replace U3 OR consult the Genie Industries Service Department Chart 9 Repair open in the WH C7 rt coil wire from the coil on the steer right directional valve item AF or Bl to the ECM U5 OR repair open in the brown ground wire circuit from the coil to the wire harness OR replace U5 OR consult the Genie Industries Service Department Repair or replace the steer directional valve cartridge item AF or Bl
197. s of the machine with a strap or other suitable device 13 Remove the pin retaining fasteners from the number 1 inner arm pivot pins item 11 at the steer end of the machine Use a slide hammer to remove the pins 14 Attach a lifting strap from an overhead crane to the steer end of the scissor arms 15 Slide the forks from a forklift under the scissor arms at the non steer end of the machine 16 Raise the scissor arms up with the overhead crane until the number 1 inner arm will clear the level sensor box Component damage hazard Be CAUTION careful not to damage the level sensor box limit switch or level sensor while moving the scissor assembly SCISSOR COMPONENTS 17 Move the scissor assembly towards the non steer end of the machine slightly and to one side of the machine until one of the scissor arm wear pads is accessible Do not allow both wear pads to slide out of the drive chassis ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the drive chassis 18 Remove the old wear pad Note the position of the wear pad before it is removed so when the new one is installed it will be in the correct position 19 Install the new wear pad 20 Move the scissor assembly towards the other side of the machine until the other scissor arm wear pad is accessible ADANGER Crushing hazard The scissor assembly will fall if both wear pads are allowed to slide out of the
198. se AF Steer left right 8 B Shuttle valve brake release AG Platform up Hand pump manual brake release AH Brake circuit D Platform lowering valve Al Drive forward reverse E Orifice platform down circuit AJ Check valve brake circuit F Accumulator AK Check valve steer circuit Part No 72876 Genie GS 1530 and GS 1930 6 36 April 2003 Section 6 Schematics E Hydraulic Schematic from serial number 17408 to 35799 April 2003 Section 6 Schematics REV B Hydraulic Schematic from serial number 35800 to 59999 M L K J H G F E D B A LIFT LEFT RIGHT 1 CYLINDER STEER STEER DRIVE MOTOR DRIVE MOTOR LEFT RIGHT 4 z oe q T Y7 Ael No 2 1 03 CU IN 16 9 cc O Sem J The lift cylinder orifice is located underneath the fitting on the lift cylinder LIFT S1 S2 M1 M4 3 YA NN M Y3 BK Br Y 0 7 bar 7 i 4 z al T PM 0 040 m X M 68 10m Ye Vi M Y5 eS _ CN BJ Y8 d d N EM 5 TP BH belie TY 0 7 bar 0 ran Eh 3000 to 3200 psi BC Ye 207 to 221 bar 6 4 a 1 m 3500 ps
199. serial number 21263 to 25141 Section 6 Schematics April 2003 E Electrical Schematic REVC from serial number 25142 to 28936 rapa 1 76 78F WH RD c C c RET WH A A M KS1 30 86 CR48 41 BL B B P A KEY SWITCH ee 5 i E LL ue CN T RELAY 87 85 BK D D d r 9 TO U5 OR E E 1 M M vh ee dece d qeu ee n CB2 P1 i B 20 7A EMERGENCY T Tf CIRCUIT STOP 2 BREAKER PLATFORM CONTROL 39C NC 4 NO 4 N CHO 4 IE E H 1 i ai M T LS6 H5 PS2 LS7 Vy GROUND DOWN ALARM PLATFORM POTHOLE CONTROL LIMIT OVERLOAD GUARD zig PERENNI ELI HIT SWITCH PRESSURE SWITCH TS66 SWITCH 3 PLATFORM OPTION UP DOWN SWITCH o C 8 S LS8 5 3 POTHOLE GUARD SWITCH 30 6 i e 3 CR5 m gt gt gt m m og gt pres 4 HORN RELAY 8 x og gt E 2 9 238 i 8 i N Z 5 5 md 6 9 us 87 Te
200. son working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death ADANGER Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Be sure to wear protective eye wear and c other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workp
201. st to the long side of the tilt level sensor box and the Y on the level sensor base closest to the short side of the tilt level sensor box Failure to install the tilt level sensor as instructed could cause the machine to tip over resulting in death or serious injury Non steer end MEM 17 Install the level sensor box onto the machine Install the level sensor box retaining fasteners scissor chassis tilt level sensor level sensor box alarm box retaining fastener level sensor retaining fastener 18 Connect the wiring harness to the level sensor limit switch and alarm panogo 19 Turn the key switch to the ground control and pull out the red Emergency Stop button to the ON position at the ground controls Part No 72876 Genie GS 1530 and GS 1930 4 43 Section 4 Repair Procedures April 2003 GROUND CONTROLS 20 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Be sure there are threads showing through the top of the adjusting fasteners Result The tilt sensor alarm should not sound 21 Raise the platform slightly 22 Return the safety arm to the stowed position 23 Lower the platform to the stowed position 24 Raise the machine approximately 2 inches 5 cm 25 Remove the blocks from under both wheels 26 Lower the machine and remove the jack 27 Remove the blocks from the wheels at the non steer en
202. t Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 SCISSOR COMPONENTS 37 Remove the external snap rings from the number 1 center pivot pin index 8 38 Use a soft metal drift to remove the number 1 center pivot pin index 8 Bodily injury hazard The number ACAUTION 1 outer arm index 19 may become unbalanced and fall if not properly supported when the pin is removed 39 Slide the number 1 outer arm index 19 to the non steer end and remove it from the machine Bodily injury hazard The number ACAUTION 1 outer arm index 19 may become unbalanced and fall if not properly supported when it is removed from the machine Note the position of the wear pads before the arm is removed so when the scissor assembly is installed they will be in the correct position 40 Attach a lifting strap from an overhead crane to the number 1 inner arm index 9 Do not apply any lifting pressure 41 Remove the pin retaining fasteners from both of the number 1 pivot pins index 10 at the steer end of the machine Use a slide hammer to remove the pins 42 Remove the number 1 inner arm index 9 from the machine Bodily injury hazard The number ACAUTION 1 inner arm index 9 may become unbalanced and fall if not properly supported when removed from the machine REVA How to Replace the Scissor Arm Wear Pads Remove the platform See 2 1 How to Remove the Platform
203. t U6 through battery quick disconnect QD1 through the 275A fuse F6 to the battery B5 continuity Check for continuity in the ground cable circuit from terminal A1 at pump motor M5 to the M terminal at motor controller U6 continuity Continued on the next page 20V or more bad 20V or more no continuity Activate the lift function and check voltage on terminal M at U6 20V or more Replace U6 OR consult the Genie Industries Service Department Repair or replace the wire circuit from the platform controls to CR48 OR repair or replace the CR48 socket OR replace CR48 Replace positive battery cable from the B terminal at U6 to D1 at 5 Replace the cable from the B terminal at U6 to QD1 OR repair or replace QD1 OR replace the cable from QD1 to F6 OR replace F6 OR replace the cable from F6 to B5 Replace ground cable from terminal A1 at M5 to terminal M at U6 REVA Repair open in the ground cable circuit from terminal A1 at M5 to terminal M at U6 OR replace M5 OR consult the Genie Industries Service Department Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts ioa ree LLL REVA CHART 2 Check for continuity in Replace ground cable the ground cable circuit nity from terminal B at U6 to from terminal B at U6 QD1 OR repair or through QD1 to the replace QD1 OR replace battery 5 the cabl
204. tely turn to the left Continue holding the switch while observing the pressure reading on the pressure gauge 7 Turnthe machine off Hold the steer relief valve with a wrench and remove the cap item AE or BF 8 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure JA TT T3113 Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve pressures higher than specifications 9 Install the relief valve cap 10 Repeat steps 5 through 8 to confirm the relief valve pressure Part No 72876 Genie GS 1530 and GS 1930 4 65 Section 4 Repair Procedures April 2003 FUNCTION MANIFOLD 6 4 Valve Coils How to Test a Coil A properly functioning coil provides an electromotive force which operates the solenoid valve Critical to normal operation is continuity within the coil that provides this force field AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Tag and disconnect the wire harness from the coil to be tested 2 Test the coil resistance Result The resistance should be within specification plus or minus 30 Result If the resistance is not within specification plus or minus 30 replace the coil Val
205. th baking soda and water Perform this procedure after fully charging the batteries Fora more accurate determination of battery condition fully charge the batteries and allow the batteries to rest 24 hours before performing this procedure to allow the battery cells to equalize 1 Puton protective clothing and eye wear 2 Besure that the battery cable connections are free of corrosion 3 Be sure that the battery retaining fasteners and cable connections are tight REVC Remove the battery vent caps from all batteries and check the specific gravity of each battery cell with a hydrometer Result If any battery cell displays a specific gravity of less than 1 026 the battery must be replaced Check the battery acid level of each battery If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill Install the battery vent caps 7 Check each battery pack and verify that the batteries are wired correctly a quick disconnect QD1 b 275A fuse F6 C batteries B5 3 8 Genie GS 1530 and GS 1930 Part No 72876 September 2006 Section Scheduled Maintenance Procedures REVC B 2 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage
206. the entire proportionally controlled speed range Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 3 Models with lift function enable button Press and hold the lift function enable button Models with drive function select button Press the lift function select button swe Genie Genie day a lift function enable button BN9 b lift function select button BN9 drive function select button 8 CHECKLIST B PROCEDURES Press and hold the function enable switch on the joystick Raise the platform approximately 4 feet 1 2 m from the ground Models with lift function enable button Release the lift function enable button Models with drive function select button Press the drive function select button Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when your reference point on the machine passes over the finish line Refer to Sec
207. the key switch to the off position 9 Wait a few seconds and then turn the key Switch to platform controls Result The error light on the top of the platform control box should go out and Code 47 should not be present on the diagnostic display at the battery module side of the machine Result If the error indicator light is still on or if code 47 is present on the diagnostic display repeat steps 5 through 9 10 Turn the key switch to the off position 11 Close the lid and install the fasteners 4 4 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 1 3 Controller Adjustments Platform lift speed and raised drive speed controlled by the ECM which is located in the battery pack module tray are adjustable to compensate for wear in the hydraulic pump and drive motors The raised drive speed and lift speed are determined by the percentage of total controller output For further information or assistance consult the Genie Industries Service Department ADANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or
208. the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS Genie a function enable switch SW5 b joystick controller JC1 with thumb steering rocker SW6 e horn button BN5 d machine on incline button e lift function select button BN9 f drive function select BN8 g red Emergency Stop button P2 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage Press and hold the horn button Result The diagnostic display will show the raised drive speed percentage Any change in software settings will not take effect until the key Switch is turned to the off position Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS 1 4 Software Configuration The ECM Electronic Control Module contains programming for all configurations of the Genie GS 1530 and GS 1930 The platform controls can be adjusted to a different configuration by changing the combination of the DIP switch settings The DIP switch is located on the circuit board inside the platform control box DIP switches have two positions on or orr When reading the DIP switch code in the D P Switch Code Chart the oN and orr are represented by the numbers 1 on and O orr Select a test area that is firm level and free of obstructions R
209. tice 2 2 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 2 Specifications REV Machine Specifications GS 1932 Australia Outdoor SPECIFICATIONS Performance Specifications GS 1932 Australia Outdoor Batteries Drive speed maximum Type 6V DC Platform stowed 2 5 mph 40 ft 10 7 sec Group T 105 4 km h Quantity 8 12 2 m 10 7 sec Battery capacity maximum 225AH FISH 40 EA Reserve capacity 25A rate 447 minutes 0 7 km h 12 2 55 sec Fluid capacities Braking distance maximum Hydraulic tank 5 gallons 18 9 liters High range on paved surface 2 tt 61 cm Hydraulic system including tank 5 5 gallons 20 8 liters Load capacity maximum Tires and wheels Platform retracted 500 Ibs 227 kg Tire size solid rubber 12x4 5x8 6 in Platform only 250 Ibs 30 5 x 11 4 x 21 8 cm 113 kg Extension only 250 Ibs Tire contact area 9sqin 113 kg 58 sq MM Function speed maximum from platform controls Overall tire diameter 12 in with 1 person in platform 30 5 cm Platform up 15 to 17 seconds Wheel diameter 8 6in Platform down 22 to 24 seconds 21 8 cm Airborne noise emissions 70 dB Wheel width 4 5 in Maximum sound level at normal operation workstations 11 4 cm A weighted Castle nut torque dry 300 ft Ibs Gradeability 25 406 7 Nm Castoshutsorque NE Continuous improvement of our products is a For operational specifications re
210. tics N Electrical Schematic from serial number 35800 to 40925 POUT2 POUT3 POUT4 POUTS POUT6 POUT7 POUT8 POUT9 POUT10 U3 PLATFORM CONTROLS PRINTED CIRCUIT BOARD POUT11 D 1 P2 EMERGENCY STOP 1 JC 1 Joystick CONTROLLER WHNL 5000 OHM POTENTIOMETER e 2 FUNCTION 4 POWER LED L19 3 4 FAULT LED L25 HIGH TORQUE LED L21 4 BATTERY LEVEL 1 4 BATTERY LEVEL 2 BATTERY LEVEL3 gt G7 BATTERY LEVEL 4 BATTERY LEVELS 4 DRIVE LED L17 4 LIFT LED L16 PLATFORM CONTROLS MEMBRANE DECAL PANEL 4 HIGH TORQUE BN6 4 HORN BN5 5 4 DRIVE ENABLE BN8 LIFT ENABLE BN9 6 H1 alarm PLATFORM CONTROLLER 7 8 Part No 72876 Genie GS 1530 and GS 1930 6 24 April 2003 Section 6 Schematics SSSR Sey Electrical Schematic from serial number 35800 to 40925 Section 3 Schematics April 2003 M 9 Electrical Schematic from serial number 40926 to 49804 REV B
211. tion 2 Specifications Part No 72876 Genie GS 1530 and GS 1930 3 15 Section Scheduled Maintenance Procedures September 2006 CHECKLIST B PROCEDURES B 9 Perform Hydraulic Oil Analysis Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced atthe two year inspection test the oil quarterly Replace the oil when it fails the test See D 1 Test or Replace the Hydraulic Oil REV B 10 Replace the Hydraulic Tank Return Filter Replacement of the hydraulic tank return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Beware of hot oil Contact with ACAUTION hot oil may cause severe burns The hydraulic tank return filter is mounted on the function manifold next to the hydraulic power unit 1 Clean the area around the oil filter Remove the filter w
212. tionThree Maintenance Procedures continued Checklist B Procedures Rev C B f Inspectthe Batteries ne eed debo ie e aue ag c e e 3 8 B 2 Inspect the Electrical Wiring eene 3 9 B 3 Inspect the Tires and Wheels including castle nut torque 3 10 B 4 Test the Key Switch oie eese ere tb perd EIER CE Mira VERDE Ged 3 10 B 5 Testthe Automotive style Horn if equipped 3 11 B 6 Test the Drive Brakes ssssssssssseeneneeeeen mmm enne n nns 3 12 B 7 Testthe Drive Speed Stowed Position sssssssssee 3 14 B 8 Testthe Drive Speed Raised Position 3 15 B 9 Perform ssis 3 16 B 10 Replace the Hydraulic Tank Return 3 16 B 11 Check the Module Tray Latch Components 3 17 Checklist C Procedure Rev C C 1 Check the Scissor Arm Wear Pads 3 18 Checklist D Procedure Rev B D 1 Testor Replace the Hydraulic Oil sssseeeneen 3 19 Section Four Repair Procedures reine Rt PEE 4 1 Platform Controls Rev B 1 1 Cdp
213. to Adjust the Steer Relief 2 Connect a 0 to 5000 psi 0 to 350 bar pressure Val gauge to the test port item AA or BA on the aive function manifold 1 Open the hydraulic power unit module tray and locate the steer relief valve on the function xa BB manifold items AE or BF gt SS E AS AA ey Sup ES AK e gt Q ON BD ww NG BE S ot Qa c 1 8 Bw I XG gt al Lo se SS 8p 9 AN js p Models after serial number 35799 Models before serial number 35800 a test port b steer relief valve test port function manifold steer relief valve function manifold oo 3 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 64 Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B FUNCTION MANIFOLD 5 Activate the function enable switch and press and hold the steer thumb rocker switch to the right Allow the wheels to completely turn to the right Continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 6 Press and hold the steer thumb rocker switch to the left Allow the wheels to comple
214. to the ON i S item Al or BJ wire to the ECM U5 OR position activate drive terminal without repair open in the brown controller in the reverse disconnecting the wire ground wire circuit from direction and check to and the negative lead of the coil to the wire see if the error indicator the volt meter to the harness OR replace U5 light at the platform brown ground wire on OR consult the Genie functions operate controls is on the coil Activate drive in Industries Service normally the REVERSE direction Department and check the voltage Be sure the circuit breaker and fuse are not tripped or blown 20V or more Disconnect the wires Be sure the batteries from the drive reverse ohms Replace the drive directional valve coil reverse directional valve are fully charged and item Al or BJ and coil item Al or Bu properly connected check resistance of the coil See Repair Section light is not on 18 to 20 ohms Repair or replace the drive reverse directional valve item Al or BJ OR consult the Genie Industries Service Department Check the connection at the ECM U5 OR replace the drive forward reverse valve cartridge item Al or BJ OR consult the Genie Industries Service Department 5 20 Genie GS 1530 and GS 1930 Part No 72876 April2003 Section 5 Troubleshooting Flow Charts REVA Machine Will Not Drive At Full Speed Be sure the circuit breaker and f
215. ull out the red Emergency Stop button to the ON position at the ground controls 15 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles Result The tilt sensor alarm should not sound Be sure there are threads showing through the top of the adjusting fasteners 16 Raise the platform slightly 17 Return the safety arm to the stowed position 18 Lower the platform to the stowed position 19 Center a lifting jack under the drive chassis at the ground controls side of the machine 20 Raise the machine approximately 2 inches 5 cm GS 1530 and GS 1930 Place a 0 62 x6 x6 inch 15 7 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine GS 1932 Place a 0 67 x 6 x 6 inch 17 mm x 15 cm x 15 cm thick steel block under both wheels at the ground controls side of the machine 2 22 Lower the machine onto the blocks 23 Raise the platform 7 to 8 feet 2 1 to 2 4 m Result The tilt sensor alarm should not sound Result The tilt sensor alarm does sound Adjust the tilt level sensor retaining fasteners just until the tilt sensor alarm does not sound 24 Lower the platform to the stowed position 25 Raise the machine approximately 2 inches 5 cm 26 Remove the blocks from under both wheels 27 Lower the machine and remove the jack 28 Center a lifting jack under the drive chassis at the batt
216. ully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position activate drive forward and drive reverse functions Check to see if the error indicator light is on at the platform controls Replace the platform controls with known operating platform controls Activate the drive function Does the drive function operate Replace the ECM U5 OR consult the Genie Industries Service Department Reset the ECM U5 by pushing in Emergency Stop button P2 to the OFF position Pull the Emergency Stop button P2 up to the ON position Check to see if the error indicator light is on at the platform controls Replace the platform controls OR consult the Genie Industries Service Department Replace the platform controls Chart 10 Refer to the chart s that are related to the error code that is displayed on U5 OR consult the Genie Industries Service Department Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April2003 Chart 10 Brake Release Function inoperative Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected Chock the w
217. umber 3 center pivot pin index 18 16 Use a soft metal drift to remove the number 3 center pivot pin index 18 17 Remove the external snap rings from the number 3 pivot pin index 19 at the non steer end of the machine Do not remove the pin 18 Use a soft metal drift to tap the number 3 pivot pin index 19 halfway out at the non steer end of the machine Remove the number 3 outer arm index 4 at the ground controls side from the machine Bodily injury hazard The number ACAUTION 3 outer arm index 4 at the ground controls side may become unbalanced and fall if not properly supported when it is removed from the machine 19 Attach a lifting strap from an overhead crane to the number 3 outer arm index 4 at the battery pack side REVA 20 Use a soft metal drift to tap the number 3 pivot pin index 19 in the other direction Remove the number 3 outer arm index 4 from the battery pack side of the machine Bodily injury hazard The number ACAUTION 3 outer arm index 4 at the battery pack side may become unbalanced and fall if not properly supported when it is removed from the machine 21 Remove the number 3 pivot pin index 19 from the non steer end of the machine 22 Attach a lifting strap from an overhead crane to the lug on the rod end of the lift cylinder for support Do not apply any lifting pressure 23 Remove the pin retaining fasteners from the lift cylinder rod end pivot pin index 5
218. until the key Switch is turned to the off position Part No 72876 Genie GS 1530 and GS 1930 Section 4 Repair Procedures April 2003 PLATFORM CONTROLS How to Adjust the Stowed Drive Speed A DANGER Tip over hazard Do not adjust the lift and or drive speed higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills will result in death or serious injury Software revision DO and higher 1 Push in the red Emergency Stop button to the off position at the ground and platform controls Turn the key switch to the off position 2 Pull out the red Emergency Stop button to the on position at the ground and platform controls 3 Press and hold the lift function select and horn buttons and turn the key switch to platform controls Result The diagnostic display will show PS 4 Release the lift function select and horn buttons Result The diagnostic display will show the maximum lift speed percentage 5 REV B Press the drive function select button Result The diagnostic display will show the stowed drive speed percentage Genie Am om J N a function enable switch SW5 b joystick controller
219. use are not tripped or blown Be sure the batteries are fully charged and properly connected With the key switch turned to platform controls and both Emergency Stop buttons pulled out to the ON position and the platform In the stowed position drive the machine in either direction Is the error indicator light on at the platform controls light is on Check voltage at the WH 39C pothole sw wire at pothole limit switch LS7 20V or more Raise the platform approximately 3 feet 0 9 m and check the voltage at the output side of LS7 20V or more Check voltage at the WH 21B pothole sw wire on the input side of limit switch LS8 20V or more Check voltage on the output side of LS8 20V or more Repair open in the WH B10 pothole sw wire from the output side of LS8 to the ECM U5 OR replace U5 OR see Chart 10A Brake Release Function Inoperative light is not on ov oV ov ov Raise the platform approximately 3 feet 0 9 m and drive the machine Does the machine drive at a reduced speed no Consult the Genie Industries Service Department Repair open in the WH 39C pothole sw wire from LS7 to the multi function alarm H5 Adjust LS7 so the pothole arm activates the switch OR replace the limit switch contact OR replace LS7 Repair open in the WH 21B pothole jumper wire from the output side of LS7 to the input side of LS8 Adjust LS8 so the poth
220. utput B4 Spare B4 Spare B5 Spare B5 Spare B6 Platform down coil Y7 output B6 Platform down coil Y7 output B7 Steer left coil Y4 output B7 Steer left coil Y4 output B8 Automotive style horn H2 option output B8 Automotive style horn H2 option output B9 Multi function alarm H5 output B9 Multi function alarm H5 output B10 Pothole limit switch input B10 Pothole limit switch input B11 Drive enable power input B11 Drive enable power input B12 Platform up TS66 input B12 Platform up TS66 input C1 Platform data link input C1 Platform data link input Yellow wire at platform Yellow wire at platform C2 Power to ECM input C2 Power to ECM input C3 Spare C3 Spare C4 Spare C4 Spare C5 Spare C5 Spare Drive forward coil Y6 output Drive forward coil Y6 output C7 Steer right coil output C7 Steer right coil Y3 output C8 Spare C8 Spare C9 Brake release coil Y2 output C9 Spare C10 Spare C10 Spare Down limit switch LS6 input C11 Level sensor signal S7 input C11 Level sensor signal S7 input Down limit switch LS66 input Part No 72876 Genie GS 1530 and GS 1930 6 5 Section 6 Schematics April 2003 Control Relay Layout REV A batteries B5 Electronic Control Module ECM U5 CR48 power relay to U5 not used before serial number 25142 lid ECM
221. ve Coil Resistance Specifications Description Specification Solenoid valve 3 position 4 way 25 to 27 Q 20V DC with diode schematic item AF and BI Solenoid valve 2 position 4 way 18 to 20 Q 20V DC with diode schematic item AG Solenoid valve N O poppet 25 to 27 Q 20V DC with diode schematic item AH Solenoid valve 3 position 4 way 1810200 20V DC with diode schematic item Al and BJ Solenoid valve 2 position 4 way 18 to 20 Q 20V DC with diode schematic item BG REV B How to Test a Coil Diode Genie incorporates spike suppressing diodes in all of its coils Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 6 4 How to Test a Coil Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repair Procedures REV B 2 Connect a 10W resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil The battery should read 9V DC or more when measure
222. vice Department Replace contact for ground controls at KS1 Part No 72876 Genie GS 1530 and GS 1930 Section 5 Troubleshooting Flow Charts April 2003 Chart 5 Platform Controls Inoperative Ground Controls Operate Normally Be sure if the Error Indicator light is on at the platform controls you refer to the specific chart that relates to the error code that is displayed on the ECM Be sure the circuit breaker and fuse are not tripped or blown Be sure the batteries are fully charged and properly connected REVA With the key switch turned to platform control and both oV Emergency Stop buttons pulled out to the ON Repair open in WH wire from KS1 to Emergency Stop button P1 OR repair open in the WH wire from P1 to circuit position check voltage breaker CB2 on the input side of the platform control contact on key switch KS1 20V or more Check if internal cam at KS1 is activating platform control contact Check voltage on output side of platform control es Replace contact for platform controls at KS1 contact at KS1 no 20V or more Replace 51 Check voltage on terminal 11 at the ECM Repair open in WH A11 keyswitch wire from KS1 U5 to terminal A11 at U5 20V or more Check voltage on OV terminal B2 at U5 Replace U5 20V or more Check voltage at the output side of the oV Emergency Stop button P2
223. xceeds the rating on the serial plate Required for Europe and Australia before serial number 48817 Installed on all machines after serial number 48816 Overload This cuts out all functions when the pressure sensor is overloaded The Emergency Stop button must be cycled before any function can be resumed Required for France Descent Delay This option halts descent at approximately 7 feet 2 1 m All controls must be released for 4 to 6 seconds before descent is re enabled Required for Europe Battery Drain Alarm When the machine is turned on and no function is activated for 10 minutes the alarm will sound once every 3 seconds This option can be activated by moving DIP switch 7 to position 1 DIP Switch Legend ON 1 OFF 0 s OFF for GS 4 OFF for and GS 1930 Se models Motion Beacon V Drain Alarm Motion Alarm Descent Delay Lift Drive Cut Out Overload Cut Out Genie GS 1530 and GS 1930 Part No 72876 April 2003 REV B DIP Switch Settings Diagnostic display code o0 HY YUU DIP switch code 00000000 Options None Diagnostic DIP switch code 00000100 Options descent delay Diagnostic display code o WOU ONY DIP switch code 00001000 Options overload cut out Diagnostic display code os HOUT UU DIP switch code 00010000 Options lift drive cut out Diagnostic display code o4 HUT DIP switch code 00100000 Options mot
224. ystem relief valve on the function manifold item BC e a P BB X Gre BK a test port b system relief valve lift relief valve d function manifold REV B 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the test port on the function manifold item BA 3 Chock both sides of the wheels at the steer end of the machine 4 Remove the platform controls from the platform Perform this test from the ground with the platform controls Do not stand in the platform 5 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Press and hold the function enable switch 7 Move and hold the joystick fully in either direction while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications 8 Turn the machine off Hold the system relief valve with a wrench and remove the cap item BC 9 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure A DANGER Tip over hazard Failure to adjust the relief valves to specification could cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve pressures higher than specifications 10 Install the relief valve cap Genie GS 1530 and GS 1930 Part No 72876 April 2003 Section 4 Repa

GS-1930

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